INESS

CH INING BUS
R MA
YO U
RK ING
MA
N CH
BE

a ke s
hat M ?
W S ho p
aT op n s iv e benc
hmark in
a
g
t
p
a
r ogram
from su
for
rveys
e h e g d ps
s is a compr n d s iz es. Usin e s , T op Sho
op s
Top Sh types a ining b
usines
ational
and
s ho p s of all m a c h s o p e r
machin
e ber o f well a s in
t e d b y a num r p ra c tices as o m p e t itivenes
comple opfloo c la s s c ch
e s o p timal sh f in e w o r ld - le a d e rs of ea
identifi hat d e ar the
m e t r ic s t . E ach ye p.
b u s in e s s
a n u factu r in g
M a c h ine Sho
m odern
e parts
discret f e a t u red in M s
r y a re . shop
catego lea d ing U.S
pare to
rs com efforts
ce ind ic ato
p rovement
rforma
n uous im
u r key pe yo u r contin ctices
ow yo guid e ted pra
 See h a ta to ss -re la
rking d busine
benchma inin g- and hop
U se
o f top ma c h
rn M achine S ate
ode particip
t
abreas d in M o
 Stay r o file o w t
e to be
p out h ops
e chanc t an d find /topsh
 Ha v
6 rep o
lin
r e.com
k out the 201 m at mmson
Chec progra
nex t year’s
in

pS hops
e.co m/ To
onlin
mms
 Top Shops
Survey
Page 22

mmsonline.com

All-Inclusive
Automation

JANUARY 2017
A property of Gardner Business Media
Chipbreakers for Steel
Together with the new IC8150, IC8250
and IC8350 grades, ISCAR’s innovative
chipbreakers designated F3P, M3P and
R3P, designed especially for machining steel.
F3P - Chipbreaker for Finish Machining
M3P - Chipbreaker for Medium Machining
R3P - Chipbreaker for Rough Machining

Together with the new IC6015 and IC6025

grades, ISCAR’s innovative chipbreakers
designated F3M, M3M, and R3M,
designed for machining stainless steel.

F3M - Chipbreaker for Finish Machining

M3M - Chipbreaker for Medium Machining
R3M - Chipbreaker for Rough Machining

Machining Intelligently
ISCAR HIGH Q LINES
 ISCAR's Winning Edge
Turning Innovations

High Gear Turning

Shortens Your Chips
Under All Cutting Conditions!

F3P M3P R3P F3M M3M R3M

Finishing Medium Roughing Finishing Medium Roughing

ISCAR METALS INC.

Tel+1 817 258 3200, Tech Tel 1-877-BY-ISCAR
Fax+1 817 258 3221, info@iscarmetals.com
www.iscarmetals.com
 Introducing the AC8025P Grade
Increase Productivity and Tool Life for Greater Cost Savings

P
Featuring our new Absotech Platinum CVD Coating, the AC8025P Grade significantly
reduces your machining costs. The high adhesion strength, smooth surface, reduced
tensile strength and chipping resistance of Absotech Platinum increases productivity and
ensures a longer tool life. What’s more, our AC8025P Grade covers a wide range of steel
turning applications. Request a sample today from engineering@sumicarbide.com
and start reaching your 2017 cost savings initiatives.
Steel

GLOBAL SUPPORT. GLOBAL SOLUTIONS.

1001 Business Center Drive

Mt. Prospect, IL 60056

(800) 950-5202
www.sumicarbide.com
 MOVING COLUMN
COMBINATION TABLE
HORIZONTAL
MACHINING CENTER
Tony Brandt, Brandt’s Custom Machining, Mansfield, Ohio:
“Every job shops dream machine!”
• Ground and induction hardened box ways • Travels 63” x 53” x 40”
• 32” .001° B-Axis rotary table + 63” x 32” flat table • 0 - 6,000 RPM spindle speed
• 35 HP spindle motor and 2 speed gearbox • 40 tools arm type ATC
• Machine base weight 44,000 lbs. • 4 screw type chip conveyors

$299,900

AHC-1600

32” .001° B-AXIS

ROTARY TABLE
+ 63” X 32”
FLAT TABLE

www.AbsoluteMachine.com
800.852.7825
sales@AbsoluteMachine.com
Hurco Companies, Inc. | One Technology Way | Indianapolis, IN 46268 | 800.634.2416 | info@hurco.com | HURCO.com
Machines shown with options. Information may change without notice.
 CONTENTS
JANUARY 2017 ■ VOLUME 89, NO. 8 ■ MMSONLINE.COM

70

FEATURES
70 No Part Left Behind
The right mindset, the right five-axis technology and
an intuitive approach to palletization help Omega Plastics
extend automated control to the majority of its high-mix work.
BY MATT DANFORD

78 78 Turn-Mill Technology Improves

Industrial Motor Performance
By replacing a welding process to create rotor cooling channels
with multitasking machining from a solid forging, Siemens
Norwood in Ohio has realized improved induction motor
vibration qualities and much faster overall rotor production
times. BY DEREK KORN

84 JIMTOF: A Strong Embrace of IIoT

The recent Japan International Machine Tool Fair reflects the
rapid move toward smart factories in which smart machines are
fully networked. BY MARK ALBERT

84
ABOUT THE COVER
A new machining center and a modified fixturing system have enabled Omega Plastics
to automate not just electrode manufacturing and ram EDM operations, but also
metalcutting of its largest parts, including mold bases. Read more on page 70. (Photo
courtesy of Jerry Heckendorn, business development manager at Omega Plastics Inc.)

8 MMS January 2017

 MACHINIST’S
SAFETY GLASSES.

Change your shop’s view of complex jobs.

If you’re looking for a powerful CAM software that makes complex jobs seem
like a day at the beach, GibbsCAM is YOUR CAM software solution.

Gc GibbsCAM®
800-654-9399
www.GibbsCAM.com

www.3dsystems.com

Solid 2-5 Axis High-Speed Multi-Task Swiss Tombstone

Turning Mill/Turn Wire-EDM
Modeling Milling Machining Machining Machining Machining
 CONTENTS
RAPID TRAVERSE
26 How Additive Manufacturing Increases Milling Feed Rates
30 Thread Mill Without a Pilot Hole
32 Robots Armed for More Than Machine Tending

COMMENTARIES AND COLUMNS

18 Mark: My Word
26
20 The Z Axis
22 One-Off
36 Deciding Factors
40 Competing Ideas
44 The View from My Shop
62 Quality Gaging Tips
66 CNC Tech Talk
144 Gardner Business Index: Metalworking

TOP SHOPS COMPANY PROFILE

88 88 Human Resources Winner: Mallory Industries

BETTER PRODUCTION
90 Precision Profiler Opens Opportunity for Larger Aerospace Parts
98 Shop Vac Reduces Unscheduled Downtime, Safety Concerns
106 Toolholding for Heavy-Duty Machining

INDUSTRY AND PRODUCT NEWS

12 Web Extras
14 MMS Connect
90 48 Shop Talk
60 Meeting Dates
116 Tooling and Workholding
126 Systems and Software
130 Modern Equipment Review
Spotlight: Turning

ADVERTISERS
140 Business Opportunities
141 Index of Advertisers
130

10 MMS January 2017

 DNM 4500

DNM 5700

DNM 6700

Global Standard
Vertical Machining Center

DNM series
DNM 4500
DNM 5700 Highest Machining Capacity in its Class
DNM 6700 - Increased cutting space, table size, allowable load and
spindle power/torque

Direct-Coupled Spindles (Standard)

- Reduced idle time with faster tool change
- Improved surface finish
- Improved tool life
- Less maintenance

Eco-Friendly, Easy Operation

- Easy Operating Package program guide
- Converstational programming
www.DoosanMachineTools.com - Reduced set-up time
DMTA.Sales@doosan.com - Grease lubrication system
MMSONLINE.COM
Web Extras | mmsonline.com
00:27
MMS Extra is Modern Machine Shop’s
free email newsletter. To subscribe,
visit mmsonline.com/sub/newsletter.
12 MMS January 2017 mmsonline.com
TAKEAWAYS FROM EDITORIAL TRIPS TO JAPAN
Last November, Executive Editor Derek Korn and
Editorial Director Mark Albert traveled to Japan:
Mark Albert to attend the Japan International
Machine Tool Fair (JIMTOF), and Derek Korn to
visit various facilities as the guest of DMG MORI.
Both editors gathered photos and information
from their trips.
In addition to Mark Albert’s JIMTOF feature on
page 84, you can find a slideshow from his trip at
short.mmsonline.com/jimtof16.
See Derek Korn’s report and slideshow encom-
passing his visits to DMG MORI’s Tokyo head-
quarters, Iga manufacturing campus and JIMTOF
at short.mmsonline.com/japan.
VIDEO: THE IMPACT OF A
HORIZONTAL MACHINING CENTER
In a new video filmed on-site at Tri-State Tool
Grinding, a Cincinnati, Ohio-based machine shop,
Editor-in-Chief Peter Zelinski interviews Quality
Manager Michael Newcomb about a transition
many small shops contemplate: switching from
vertical to horizontal machining. The video details
how the shop realized significant efficiency ben-
efits due to fewer part setups with a new Makino
a61nx horizontal machining center. Watch the
video at short.mmsonline.com/newcomb.
02:08
MAKE MMS ONLINE ZONE PAGES
PART OF YOUR SEARCH
If you’re looking for in-depth coverage of specific
technology areas or processes, be sure to take
advantage of MMS Online’s Zone pages. These
41 pages each present the latest feature articles,
blog posts, product releases and other content
in technology-, industry- and process-specific
silos. Click the “Zones” button at the top of the
website, or visit mmsonline.com/zones.
 Dynamics at their peak

The economical way to mill grooves. Our carbide circular milling tools are used for groove milling,
helical interpolation, thread milling, T-slot milling and special applications with cutting diameters ranging
from 9.3 mm to 35.7 mm (.36699 to 1.40699). The vibration resistant carbide shanks, patented insert
seating, and optimized geometries and grades ensure maximum cutting potential, outstanding chip
www.hornusa.com
removal, and reliable machining processes. www.hornusa.com

H O R N – E X C E L LE N C E IN T E CH N OLOGY

GROOVING PARTING OFF GROOVE MILLING BROACHING PROFILE MILLING REAMING

MMS CONNECT
CONNECT
WHY FORMING A MACHINE-TOOL
BUYING COMMITTEE IS A GOOD IDEA
facebook.com/mmsonline
There are many factors to be considered before acquiring a new machine
tool, and a lot of questions have to be asked and aswered prior to select-
ing the right CNC machine. With such a decision, it is important to
consider how the purchase will touch all the relevant departments of a
shop. Read the full story pinned to the top of our Facebook page.

LATHE WITH Y-A XIS

MOTION, ATC PROVIDES
FLEXIBILITY
youtube.com/mmsonlinevideos
Hwacheon offers C1 series CNC lathes
with Y-axis motion and ATC-tended,
“three-stack” turrets. The turret can
present tools to both the main and
subspindle, and includes six stations
with Capto toolholder interfaces for
00:27 02:08
auto tool change-out.

GUIDE TO BUYING 2017 TOP SHOPS SURVEY

MACHINE TOOLS
techspex.com
Te c hs p ex n ow h a s a K n ow l e d g e C e nte r
called “Guide to Buying Machine Tools” that
will share valuable exper tise intended to
help machine shops make smart decisions
on their next machine purchases. Browse
the ar ticles and product showcase by
v isiting shor t.mmsonline.com /te chspex,
a n d c h e c k b a c k i n a c o u p l e m o nth s fo r
more content.
NOW LIVE
bit.ly/mmstopshops
Modern Machine Shop’s Top Shops benchmark-
ing program is what spurred the idea to start our
Top Shops LinkedIn group. The 2017 survey is
now live and will run through February. It can be
accessed at survey.mmsonline.com/topshops.
Plus, don’t forget you can find results from past
surveys and numerous articles offering analysis
of sur vey findings in our Top Shops Zone at
mmsonline.com/topshops.

FIND OUT MORE: VISIT OUR TWITTER PAGE

twitter.com/mmsonline
Here is a sampling of some of our recent tweets—little bits of
information in 140 characters or less. Follow us on Twitter to read more
stories like these.
• Editors of #AdditiveManufacturing magazine (@AddMfgMedia) share
insights from the 2016 AM Conference: short.mmsonline.com/AM2016
• One next-step advancement for #cobots: specialized grippers from
@SCHUNKINC short.mmsonline.com/schunkgrip
• Fusion of #waterjet, #laser opens new #machining possibilities:
short.mmsonline.com/fusion

14 MMS January 2017 mmsonline.com

KARL TAYLOR, DAN HENDRICKS
AND DAN KRANZ
Waconia Manufacturing
Waconia, Minnesota

BR8150IL

BR6150IL
BR6100IL

The NEW Milltronics Bridge Mills are built to machine big parts, fast. Featuring huge travels ranging from
100x50x28" to 200x80x28", rapid traverse rates up to 1,000 IPM and 10,000-15,000 RPM spindle speed
options the BR Series is all about value, performance, productivity and profit. Call 888-999-1440 to learn
more about the new bridge mills or see the full BR product line up at milltronics.com/products/br8200il/
STAFF

6915 Valley Avenue

Cincinnati OH 45244-3029
P 513-527-8800
Fax 513-527-8801
gardnerweb.com
mmsonline.com

Richard Kline, CBC Chairman and CEO

Melissa Kline Skavlem COO
Richard Kline, Jr. President
Publisher Travis Egan Group Publisher
Travis Egan Tom Beard Senior V.P., Content
tegan@mmsonline.com
Steve Kline, Jr. Director of
Associate Publisher Market Intelligence
Kent Luciano
kluciano@gardnerweb.com Ernest Brubaker Treasurer
Editorial Director William Caldwell Advertising and
Mark Albert Production Director
malbert@mmsonline.com Kate Hand Director of Editorial
Editor-in-Chief Operations
Peter Zelinski
pzelinski@mmsonline.com Jeff Norgord Creative Director

Executive Editor Dave Necessary Director of Marketing

Derek Korn and Events
dkorn@mmsonline.com
Managing Editor
Emily Probst PUBLISHER OF
eprobst@mmsonline.com METALWORKING
Associate Editor • Additive Manufacturing
Matt Danford • Modern Machine Shop
mdanford@mmsonline.com • Modern Machine Shop Mexico
Associate Editor • MoldMaking Technology
Stephanie Hendrixson • Production Machining
shendrixson@gardnerweb.com • TechSpex
Copy Editor COMPOSITES & PLASTICS
El McKenzie • Composites World
emckenzie@gardnerweb.com • Plastics Technology
Assistant Editor • Plastics Technology Mexico
Jedd Cole AUTOMOTIVE
jcole@gardnerweb.com • AutoBeat Daily
Creative Department Manager • Automotive Design & Production
Rhonda Weaver FINISHING
rweaver@gardnerweb.com
• Products Finishing

CHANNEL PARTNERS AUDITED BY

Subscription Inquiries: For questions or issues related

to your subscription, please call 513-527-8800
or email subscribe@mmsonline.com.

16 MMS January 2017 mmsonline.com

 The BETTER Toolroom Mill

The Fryer MB-R Series is the ideal machine for your toolroom, job shop, repair or fab house. Multi-
mode operation allows you to run manual, semi-automatic or full CNC. Designed and built to be the
finest toolroom mills available, these machines are easier to use, faster to set-up, more accurate and
last longer than any other toolroom mill. Equipped with the powerful but easy to use Siemens – Fryer
control, the MB-R series allows you to make parts faster with less key strokes and a lower learning curve.

A Run manual, semi-auto or full CNC A 30”, 40” and 60” models
A 40 taper 8,000 RPM spindle A Teach mode, probing, handwheel run
A 12 or 20 tool ATC A One button set-up keys
A Rigid tapping with peck feature A Solid model 3D graphics
A Regenerative drives save 40% A World class construction
power consumption A Build to last decades

845.878.2500
The Toolroom Company FRYERMACHINE.COM
MARK: MY WORD Commentary
Red, Yellow, Green
Data-driven manufacturing should be color-coded for simplicity.
Data-driven here. Data-driven there. Internet
of this. Internet of that. Industry 3.0, 4.0, 5.0 (Who’s
in charge of counting this, anyway?). Computing
in the cloud, in the fog, in the mist, at the edge, at
the core. It can all seem a little crazy.
So let’s step back and remember that it is all
about Red, Yellow, Green. Red signals that a
machine is not running. Yellow signals that a
machine may need help to keep running. Green
signals that a machine is running—for now.
It’s that simple. Getting everyone in the company
to have a Red, Yellow, Green mentality would get
the entire organization focused on what really
counts: what is (or is not) happening on the shop
floor. By company, I mean any manufacturing
enterprise, from the family job shop to the global
conglomerate. By everyone, I mean the CEO and
the Board of Directors all the way to the shopfloor
staff—machine operators, CNC programmers,
toolroom attendants and so on. Engineering, Sales,
IT, HR and all levels of management must be
focused on Red, Yellow, Green as well.
MARK ALBERT
EDITORIAL DIRECTOR
MALBERT@MMSONLINE.COM
“Thinking Red, Yellow, Green
gets everyone focused on what
really counts.”
Of course, the significance of these colors is
different from person to person in the company.
Each color represents a spectrum of meaning,
nuances, and degrees of urgency or alertness.
Each color is a constant call to action that covers
a range of decisive responses and levels of empow-
erment. Not doing something may be as valid a
18 MMS January 2017 mmsonline.com
response as hitting the emergency stop button,
as long as the rightness of the response is equally
clear and unequivocal.
Here are some more thoughts on keeping Red,
Yellow, Green in mind.
The need to know is basic. A huge benefit
of connecting machines to a network is making
these colors and their meanings visible to the entire
enterprise. This is unifying and energizing.
Take it personally. Everyone must be respon-
sible for reacting to Red, Yellow, Green in their
particular spheres. It should be a top management
priority to instill and enforce this responsibility.
Those rascals in IT, for example, must act as key
enablers of this organizational principle.
Red is a friend. Never ignore a friend. Red
sets priorities, governs resource allocations, teaches
lessons and validates lean manufacturing efforts.
Red means GO! There are good and bad reasons
for a machine not to be running. The right attention
to Red is what matters.
Watch out for Green. The temptation is to
allow Green to mean STOP—stop watching, stop
looking for hidden waste, stop thinking about
what’s next. Green is linked to high productivity
and a desirable overall equipment efficiency (OEE)
rating, but it must also be linked to profitability.
It’s a numbers game. These color-coded
visual signals always point to numerical values.
The intent of data-driven manufacturing is to give
decision-makers the numbers needed to act in
ways that improve manufacturing processes. No
guesses. No assumptions.
Moving to data-driven manufacturing, the
Industrial Internet of Things or Industry 4.0 is not
easy. Thinking Red, Yellow, Green should prevent
unfocused thinking from adding complexity to the
urgent, demanding task at hand: getting the most
from the machines on the shop floor.
THE Z AXIS Commentary
The Unseen Capacity
Capacity utilization figures conceal the likelihood that it is a particular type of
capacity going unused. Also: the debut of a new column.
Manufacturing capacity utilization in the United
States has been about 76 percent throughout the
past year, per the Federal Reserve. In other words,
about 24 percent of the capacity in the average
plant has been unused. But manufacturing portal
MakeTime says there is a story inside this metric
that the figure itself isn’t telling.
MakeTime, based in Lexington, Kentucky, is
like a broker for U.S.-based machining. Shops
the company qualifies through on-site evaluations
can join its network and make their open capac-
ity available. Buyers of machined parts bring their
work to MakeTime, which prices jobs and guar-
antees on-time completion by these suppliers.
With around 700 shops now in the network, the
company has a perspective on open capacity.
PETER ZELINSKI
EDITOR–IN-CHIEF
PZELINSKI@MMSONLINE.COM
“It is like there is an outsource
nation embedded inside of
U.S. machining capacity.”
Director of Business Operations Ryan Kelly
says the story the U.S. utilization number isn’t
telling relates to the type of capacity being used.
Throughout MakeTime’s network, older or simpler
machine tools are waiting, he says. A recent one-
day view of the network showed 7,200 hours of
available open time for basic turning and 7,000
hours available for three-axis vertical milling.
Meanwhile, more sophisticated machining
capacity is committed. Indeed, Mr. Kelly says the
demand for five-axis machining surpasses the
network’s available capacity by at least two times.
20 MMS January 2017 mmsonline.com
There is a mismatch between high-complexity
machining and simpler machining (a mismatch
the company is addressing by recruiting more
five-axis shops), and this same phenomenon likely
exists throughout U.S. manufacturing.
If true, then machining is more strained than
the utilization implies. A shop running at 70 percent
might effectively be booked if that last 30 percent
represents simple machines that cannot be applied
to the complex work the shop is now seeing.
But another implication of the mismatch is
something Mr. Kelly sees as a business developer,
and as someone with hopes for both the company
he works for and the success of U.S. manufactur-
ing overall. There is an opportunity there, he says.
Likely it’s an opportunity for reshoring. All of that
basic machining capacity that is available could
be put to use at an economical price. The demand
for machining within the United States may have
shifted toward higher-value work, but the basic
machines haven’t disappeared. As a result, it is
like there is an outsource nation in our midst—a
virtual, invisible, domestic outsource supplier
embedded inside of U.S. machining capacity. What
might come of putting all that capacity to use?
Something else: With this issue, we debut a
new column called “The View from My Shop.”
Find it on page 44. Each month, a different guest
columnist involved in leading a machining facility
will offer an insight he or she has learned, applied
or come to appreciate in this work. The column
will add to the voices in this magazine, and provide
an additional outlet for experiences and perspec-
tives that are useful to share. Look to the column
to learn how other shop leaders like you see their
roles. And if you would like to be a future guest
writer for the column, feel free to contact me.
 SEEING
IS BELIEVING
Amazing!
¡Fantástico!

Incredible!

Wow!

Ótimo!

ONCE YOU SEE IT,

YOU’RE GOING TO NEED TO TRY IT.
We challenged large and small shops around the world to try Dynamic
toolpaths. The results are nothing short of amazing. Dramatically shorter
cycle times, with extended tool life and less strain on machines.

See it for yourself. Get it at Mastercam.com/DynamicChallenge.

www.mastercam.com
ONE-OFF Commentary

Top Shops by the Numbers

The seventh-annual Top Shops benchmarking survey is now live. Here’s helpful
information for those who have participated in the past and those who haven’t.
I’m pleased that there remains continued 4 (again)—After the survey closes, we’ll gener-
interest in our Top Shops benchmarking initiative, ate and provide a total of four data reports. Three
which includes an annual survey and awards of these are sent only to participating shops. These
program. In fact, our seventh-annual online survey cut the data into categories including type of
at survey.mmsonline.com/topshops is now live machining business (job shop, contract shop or
and will be open through February 28. captive operation), number of employees and
Over the years, we’ve maintained a core group number of parts produced. In addition, we create
of shops that routinely participate. However, we an Executive Summary, comparing responses
also get an influx of new shops each year, which between the Top Shops benchmarking group and
is why I put together this list of key numbers for the rest of the survey participants (survey partici-
everyone to keep in mind: pants receive a hard copy of this summary). That
4—The survey is divided into four categories: way, you can see how your shop’s key performance
machining technology, shopfloor practices, busi- indicators, such as net profit, spindle utilization
ness strategies and human resources. We do not and so on, compare with industry leaders. You can
also see what types of equipment, processes and
ask for specific financial figures such as gross sales
or net income. Instead, we ask shops to supply strategies those top-tier companies are leveraging.
financial measures as percentages, including net Doing so will help identify and prioritize your future
income per gross sales, annual sales growth rate improvement efforts.
and capital equipment expenditure per gross sales. 37—The Top Shops initiative includes an Honors
Our thought is that this will encourage greater Program award, which has been presented to 37
participation from shops that aren’t inclined (or shops thus far. The Honors Program highlights
successful participating companies in each of
allowed) to provide specific financial data. Nonethe-
less, all survey responses will remain confidential.the survey’s four aforementioned sections, iden-
tified by responses to select questions and follow-
up interviews by me. Those shops are profiled in
DEREK KORN Modern Machine Shop and on our website. In
EXECUTIVE EDITOR
addition, we offer a prize package that includes
DKORN@MMSONLINE.COM
a large Top Shops banner that can be displayed
“Visit survey.mmsonline.com/
in your shop, T-shirts, hats, toolbox magnets and
topshops to participate in this
so on. We also provide winners with a press release
year’s benchmarking survey.”
template that they can modify and send to various
press outlets to get the word out about winning
their award.
20—For each survey, we establish a Top Shops 1,946—The Top Shops benchmarking program
benchmarking group representing the top 20 spurred the idea to start a Top Shops LinkedIn
percent of participating machine shops, determined group. At the time of this writing, our Top Shops
by totaling the points assigned to select business- LinkedIn group had nearly 2,000 members. This
and technology-related questions. group is for decision-makers in U.S. machining

22 MMS January 2017 mmsonline.com

 A U T O M A T I O N

Automated processing offers the highest

potential for increased productivity. Methods
automation group includes design engineers,
control engineers, fl uid engineers, integration/
assembly engineers, field service/installation
engineers, electro/mechanical engineers and
machinists. We are a complete solution for
customers across the nation.
■ 30 automation engineers nationwide
■ Provide highly innovative and customized
machine tool automation solutions
■ Increase in customers bottom
line and equipment utilization,
and lower operating costs
■ In-house quoting, assembling, testing,
installation, training, run-offs, and
implementation of all automation solutions

RoboDrill
a-DiA Series
“If it fits in a RoboDrill,
it should be run in a RoboDrill.”
With a proven record of high performance, high
reliability, and low maintenance, RoboDrills are the
preferred machines in any shop.

Features:
■ FANUC 3li-B5 control ■ 660 lb table
■ 16.5 HP @ 10,000 rpm capacity
■ 7 HP @ 24,000 rpm ■ 1.5 G acceleration
■ BIG-PLUS spindle ■ Designed for
automation
■ 21 tool ATC
■ Available with
■ 1.6 second tool Pallet Changer
change

www.methodsmachine.com

CORPORATE OFFICE TECHNICAL CENTER AND SHOWROOM TECHNICAL CENTERS FROM COAST TO COAST
65 Union Avenue, Sudbury, MA 01776 Charlotte Chicago Detroit Los Angeles Phoenix San Francisco
978.443.5388 | sales@methodsmachine.com 704.587.0507 847.783.6800 248.624.8601 714.521.2507 602.437.2220 510.636.1430

M ACHINE T OOLS ■ T URNKEY S OLUTIONS ■ A UTOMATION C ELLS ■ P ARTS AND S ERVICE ■ T OOLING
ONE-OFF Commentary

facilities, including shop owners, managers, engi-

neers, programmers and other senior personnel.
We currently are limiting the group to only these
people, because we believe this exclusivity is part
of what makes this group different and helpful. Feel
free to email me at dkorn@mmsonline.com if you’d
like to join the group.
2017—This year, we introduce our inaugural
Top Shops conference, which will take place
September 5-7 at the JW Marriott in Indianapolis,
Indiana. The goal of this conference is to offer
presentations about very advanced, yet practical
tactics, processes, machining approaches and so Mallory Industries is the 2016 Top Shops Honors
on that you can readily apply soon after returning Program winner in the human resources category.
to your shop. This might include leveraging additive See why in its company profile starting on page 88.
manufacturing in a shop setting; machine tool
monitoring and data collection; cutting tool man- D o n’t fo rg et, yo u c a n f i n d re s u l ts f ro m
agement; and best practices in areas such as past sur veys and numerous ar ticles of fering
business strategies, workforce development and analysis of sur vey findings in our Top Shops
human resources. Visit topshopsevent.com for Zone at mmsonline.com/topshops. Feel free to
show information. The lineup of speakers will be email me at dkorn@mmsonline.com if you have
finalized early this year. any questions.

24 MMS January 2017 mmsonline.com

Instant VMC
Capacity

• Easy to write or import programs

• Easy to move to available labor
• Easy to set up from job to job
• Easy to run while tending another
machine
• Easy to schedule jobs
independently
• Easy to combine into a work cell

• 14”x12”x17” travel
• 30”x48” footprint
• 8-station tool changer
• 3 HP
• ProtoTRAK TMX control

southwesternindustries.com | 2615 Homestead Place, Rancho Dominguez, CA 90220 | 866-870-2061

RAPID TRAVERSE Machining Technology in Brief

How Additive
Manufacturing Increases
Milling Feed Rates
BY PETER ZELINSKI

T he promise of additive manufacturing will be

found in products that are designed to be
made this way—that is, products that take full
productivity. This is increasingly true as facilities
using this tooling adopt modern machine tools
with high acceleration rates. However, obtaining
advantage of the geometric freedom that can be a high number of flutes is problematic in cutter
realized through 3D printing. A recent successful bodies made through machining, because the
example of this relates to milling cutters. Komet’s small pockets resulting from high flute density
“Revolution” line of milling tools includes tool have to be milled out painstakingly using light
bodies made through metal additive manufactur- cuts with small tools. Additive manufacturing
ing to realize design features including a flute offers a more efficient option.
density higher than what is practical to achieve Now, high-flute-density bodies are grown
on conventionally manufactured tools. When it several at a time at Komet’s headquarters in
comes to cutting edges made of PCD (polycrys-
talline diamond) that hold the potential for more
aggressive milling, adding more flutes to the tool
directly enables faster feed rates. Thus, Komet is
actually using additive manufacturing to make
subtractive manufacturing more productive.
C ompa ny D ire ctor of Production Culle n
Morrison sees making tool bodies through 3D
printing as being the way of the future, at least
for PCD. This cutting tool material often can take
advantage of all the flutes it can get, he says. It
is capable of such high material-removal rates
in the materials it typically cuts—aluminum and
carbon fiber composite—that the number of
flutes can be the limiting factor on feed rate and

On this 10-flute tool, the narrow and deep pockets

between flutes could be produced through machining,
but the machining cycle would be complex
and long. A high helix angle for the flutes compounds
the geometric challenge. But additive manufacuring
makes this form easy to achieve—the cutter
body was grown through selective laser melting.

26 MMS January 2017 mmsonline.com

 2017 Machine Tool Product Launch

NEW XH Series
XH6300 / XH8000

NEW KL7000 Series

KL7000LY

NEW L-SY Series

L2000Y, L2000SY, L2000LSY
L2600SY, L2600LSY
L3000Y, L3000SY, L3000LSY

HYUNDAI WIA Machine America

265 Spring Lake Dr., Itasca, IL 60143
P: +1 (630) 625-5600
www.hyundai-wiamachine.com
RAPID TRAVERSE Machining Technology in Brief

Cutter bodies are grown

several at a time in each
additive cycle. Different
standard or custom tools
can be grown together in
the same build as they
are needed.

The shank of the tool is
still produced conven-
tionally, because machin-
ing is far more efficient
for a form such as this.
The head and shank are
combined through laser
welding. Welding 3D
printed heads to mass-
produced shanks will
also provide an effective
way to deliver special-
order tools.
Germany on a selective laser melting machine
from Renishaw. After these bodies are separated
via EDM from the build plate used in the additive
process, they are ready for the PCD edges to be
brazed on. Komet grows only the heads of the
tools this way, laser-welding them onto the shanks,
because the shanks can be manufactured more
economically in conventional processes.
Mr. Morrison says the advantages of additive
manufacturing for the cutter heads go beyond
The possibilites extend beyond milling. This new drill-
ing tool from Komet also leverages 3D printing. Com-
plex features of the tool provide passages through
the flutes, enabling the chips to be safely transported
out of the drilled hole. This tool design leverages
additive manufacturing for the geometrically complex
components, with machined and 3D printed pieces
assembled together to make the final tool.
flute density. There is also the flute pitch. Previ-
ously, a pitch of 4 to 5 degrees is the best the
company could efficiently achieve, because the
clearance challenges of reaching a cutting tool
past the flute in order to mill out the pocket
precluded a steeper angle than this. But in this
case as well, the geometry consideration poses
no challenge for additive. On the new tools,
Komet has produced flute helix angles ranging
to 20 degrees.
The 3D-printed tools likely will also realize
longer life, he says. The reason is coolant delivery.
With additive, coolant channels can be grown
inside the tool along snaking paths that exit
precisely where the fluid can be most effective.
On previous tools, the positioning of coolant
channels was always a compromise resulting
from the need to drill a straight hole past the
clearance obstacles in the way of this drilling.
One other advantage
of additive manufactur-
ing might be the most
transformative of all, he
says: It will permit faster
lead times for special
tools. This advantage
is particularly apparent
to th e S c h a u m b u rg,
Illinois, Komet facility
w h e r e M r. M o r r i s o n
works, because nearly
all of the manufacturing
here relates to specials.

28 MMS January 2017 mmsonline.com

 AUTOMATION MADE EASY

Simplify your operations and take the worry out of maintenance and upkeep
with factory automation solutions from FANUC. Our advanced technology,
reliable performance and lifetime customer support make it easy to get the
most out of automation.

Talk to FANUC today and see how easy automation can be.

888-FANUC-US
www.fanucamerica.com
© 2017 FANUC America Corporation. All Rights Reserved
RAPID TRAVERSE Machining Technology in Brief
With 3D printing, the range of design options for
these special tools increases, and unusual
designs specified by special-order customers
can move into production practically as soon as
they are modeled.
It will take more additive manufacturing capac-
ity to fully realize the promise of the capability for
special orders, he says. The company is explor-
ing how far to advance with this means of produc-
tion, and how quickly. As yet, there is 3D printing
Komet of America, call 800-656-6381
or visit komet.com.
Thread Mill Without a Pilot Hole
BY DEREK KORN
S uccessful job shops
tend to be the most
flexible, adaptive and
responsive of machining
businesses. There’s no
guarantee any one job will repeat, so these
companies must set themselves up to process
a w i d e va r i et y of wo r k i n a n ef f i c i e nt a n d
timely manner.
This means thoughtful decisions must be made
about what type of equipment they will use to
quickly turn a variety of jobs, often in small batch
sizes, for their customers. For example, some
shops try to standardize on the types of cutters
they use and keep loaded in a machine’s automatic
toolchanger (ATC) magazine. That way, setups
can be faster, because fewer tools have to
be added and measured/touched-off for each
new job.
Therein lies the value of a thread-milling tool.
An alternative to size-specific taps, thread mills
use interpolating motion to mill internal threads
in a variety of hole diameters. This is particularly
helpful to job shops in that they don’t have to keep
a number of taps of different sizes on hand and
don’t require special tapping heads. In fact,
Mitsubishi Hitachi Tool Engineering, a division of
Mitsubishi Materials, takes this one step further
30 MMS January 2017 mmsonline.com
capacity only in Germany. But even so, the lead
time for 3D-printed tool bodies made here is so
fast that the distance is potentially no obstacle to
serving customers in the United States efficiently.
He says one possible scenario being discussed
for custom tools is this: While the U.S. cus-
tomer’s special cutter head design is grown
additively in Germany, the Illinois facility can
simultaneously machine that tool’s shank. The
3D-printed head would then be sent to the U.S.
and welded to the shank there, ultimately still
allowing the tool be delivered within a much
tighter window than today’s manufacturing
methods make possible.
This thread-milling tool is able to drill its own pilot
hole while it is also milling threads into the hole. It is
well-suited for job shops in that a single tool can drill
and thread a range of hole diameters.
with its Epoch D line of solid carbide thread mills
that don’t require a pre-drilled pilot hole. These
tools simultaneously drill the hole as they mill the
threads, using a proprietary cutting edge shape
that is said to prevent edge tip breakage even
when machining hardened steel. (A video show-
ing this combined drilling/thread-milling operation
is found at short.mmsonline.com/epoch.)
Combining operations in this way can not
only speed overall cycle times, but it also frees
RAPID TRAVERSE Machining Technology in Brief
00:27 02:08
additional ATC carousel stations that shops can
keep loaded with other tools. In addition, the tool
load for a thread-milling process is lower than
tapping, and thread mills won’t become stuck in
Mitsubishi Materials USA HT Division,
call 248-308-2620 or
visit www.mmc-hitachitool.co.jp/en-US.
Robots Armed for More Than
Machine Tending
BY MAT T DANFORD
J ohn Lucier says he doesn’t spend nearly as
much time touting the general benefits of
par t-ha ndling robotic a r ms as he use d to.
“Machinists and machine tool people get it; we’re
over the hump,” explains the national automation
manager for machine tool distributor Methods
Machine Tools Inc. (Sudbury, Massachusetts).
“Recently, it’s been more about coming up with
that perfect mousetrap.”
Before that work can begin, a manufacturer
must understand that the proverbial bet ter
mousetrap can cover far more than just loading
and unloading machine tools. To overlook pro-
cesses like cleaning, marking, inspection and
particularly deburring is to risk missing out on the
full breadth of the opportunity afforded by robotic
automation, Mr. Lucier says.
In some cases, manufacturers struggle to
justify the capital expense of a robot arm that’s
likely to cost more than the equipment with which
32 MMS January 2017 mmsonline.com
A video of the combined drilling/thread milling opera-
tion is found at short.mmsonline.com/epoch.
a hole if breakage occurs, as can happen with
taps, especially when workpieces are made of
hard materials. Plus, right- and left-hand thread
milling can be performed with the same tool just
by changing the NC program.
The Epoch D thread mill also features the
company’s ATH coating applied using physical
vapor deposition (PVD) nanotechnology that is
said to improve the tool’s hardness and oxidation
r e s i s t a n c e c o m p a r e d to t h e p r e v i o u s T H
coating. This results in longer tool life in materials
harder than 45 HRC. These thread mills are
available in metric (M2 through M20 thread size)
and UNC (No. 1-64 UNC to 5 / 8 -11 UNC thread
size) versions. In addition, the company offers
downloadable thread milling programming macros
at its website.
it is paired—substantially more even. However
intuitive this thinking is, comparing cost percent-
ages of robot to machine isn’t a fair way to evalu-
ate whether a downstream process is suitable for
automation, Mr. Lucier says. A better comparison,
he claims, is between the cost and time associ-
ated with the manual labor that a robot arm could
replace. The argument essentially goes like this:
If the cost of manually tending a $30,000 marking
machine doesn’t substantially differ from that of
tending a $100,000 machine tool, why would a
robot arm be any less justified?
In other cases, manufacturers that eagerly take
the first step are then slow to recognize a case in
which automation begets the need for more
automation. “More often than not you’ll make
more parts an hour with a robot on your machine
tool, but more parts an hour means more parts
to deburr, too,” he explains. “It’s always ‘Look at
how much we’re cutting now, this is spectacular!
 START SPREADING THE NEWS.
If you laid all our tools side by side... well, that would be quite an undertaking; there are
more than 1,000,000 of them. Enough precision cutting tools to fill a city—in stock and
ready for fast delivery. And if you don't find what you need, we'll custom make it for you.

If we don't make it here, they don't make it anywhere.

GROOVING
THREADING
PARTING
BORING
TURNING
FACE GROOVING

KAISER TOOL COMPANY, INC.

Fort Wayne, Indiana
Shipment from 72 hours
S I N C E 19 6 4
http://thinbit.com/skym

MADE IN THE USA 888–THINBIT 8 8 8 – T H I N FA X T H I N B I T. C O M

RAPID TRAVERSE Machining Technology in Brief
But now we can’t inspect them fast enough.’ I’ve
seen this from companies with single robots
all the way up to large customers with 30-foot
rails with machines on both sides. Sometimes, it
doesn’t even enter their minds that a process can
be automated.”
One reason a process might be overlooked as
a candidate for robotic automation is complexity,
Mr. Lucier says. Loading and unloading machine
tools is one thing; programming robot arms to
precisely articulate workpieces around spinning
deburring tools (which are subject to wear over
time) is quite another. Nonetheless, deburring has
become a particular focus of late, he says, citing
the labor-intensive nature of a process that large
portions of the market still perform manually.
Tedium and repetition can lead to mistakes or
even injury, he says. What’s more, the dedication,
skill and attention to detail this process often
requires not only can be difficult to find, but might
be better applied to other value-added tasks
any way. The modular cell shown above, an
example of a high-end solution from Methods,
demonstrates what is possible and could repre-
sent a way forward for many high-production
operations, Mr. Lucier says.
Yet, he emphasizes that, much to the surprise
Methods Machine Tools Inc., call 978-443-
5388 or visit methodsmachine.com.
34 MMS January 2017 mmsonline.com
This demonstration cell is
configured similarly to many
deburring/washing field
installations performed by
Methods Machine Tools’ inte-
gration team, with tool types,
mounting configurations and
so forth differing from plant
to plant. Although only two
are visible here, this particu-
lar version has three robotic
modules: two for deburring,
and one for washing (utilizing
the high-pressure coolant
pump from a FANUC Robodrill
VMC). For video of the demo,
visit short.mmsonline.com/
debcel.
of some customers, such high-end systems aren’t
necessary in many cases. Complexity, he explains,
may well be present only in the eye of the beholder—
the shop owner who hasn’t considered an alter-
native method that might lend itself better to
robotic automation. Returning to the example of
deburring, he says he might ask a customer if
parts lend themselves to being pressed against
an abrasive brush or belt rather than being
manipulated around a cutting tool. Another option,
cyrogenic deburring, is not only similarly simple
to automate, but can also clean surfaces even as
it freeze-blasts them smooth, he says, making it
particularly useful in the medical industry. Or
perhaps a task can be automated by adding sta-
tions around existing robots instead of adding
new ones. An example of this might be a machine-
tending arm making an extra stop for simple part
measurements on an linear variable differential
transformer (LVDT) sensor or air gage.
Mr. Lucier emphasizes that there are many
different ways to mark a part, clean a part or
perform any other downstream process, and
dif ferent manufacturers have vastly dif ferent
needs. Nonetheless, these processes stand to
improve as much from robot-arm tending as
primary metalcutting operations. With the right
expertise, robotic automation can be more viable
than meets the eye. And with an open mind,
it might be simpler than it initially appears.
 Feature Machines of the Month

The Ultimate CNC

Combination Lathes
Large Capacity Models Available with up to 39.3" Swing and 200" Centers

MR Series shown with optional 8 Station Automatic Bi-Directional Indexing Disc Turret

The Perfect Machine for Most of Today’s

CNC Turning Applications... Pick the Control
that is Right for Your Turning Needs
Clausing/MultiTurn MT Series: The MT series Clausing/MultiTurn MR Series: Equipped with
features the Fanuc Oi-TD control with ‘Manual the FAGOR 8055i TC CNC Control. This user-friendly
Guide i’ programming allowing the operator to control offers both Icon-Key based conversational
generate part programs quickly and efficiently programming or Conventional ISO G-code
through the use of easy-to-understand programming. The extensive use of graphics at the
conversational style cycle prompts. Fanuc Oi-TD display means that even complex machining tasks
control package comes with all digital control and are accomplished and set-up time is minimized for
drives offering exceptional value and reliability. both experienced and beginner operators.
The extensive list of machine features include: Anti-friction PTFE material between saddle and
bed for greatly improved surface finish • Heavy-duty cast iron hardened and ground bed ways
• Triangular web bed design CNC1000/2000/3000/4000 models • Extra wide bed maximizes
support for saddle and cross slide assembly • Variable AC spindle drive motor • Automatic three
range headstock (Automatic four range headstock on CNC7000/8000 models) • Superior
headstock positive flow lubrication system • Automatic oil system to guide ways & ballscrews
• Digital AC servo drive system • Fully enclosed, interlocking guarding (optional on models with
120" centers and larger) and much more...
Available in models with: 13", 15", 18", 21", 26", 30", 31.4" and 39.3" swings
up to 200" between centers

Call 800-323-0972 for the Clausing Dealer Nearest You

or visit www.clausing-industrial.com
for detailed catalogs of the full line of Clausing Machine Tools
Over A Century in the Machine Tool Business
DECIDING FACTORS A Focus on Data-Driven Manufacturing
What It Takes to Connect
T he Industrial Internet of Things (IIoT) is no longer
only a promise. With common data definitions
for metalcutting machines specified in the MTCon-
nect standard, we now have a way to easily collect
large amounts of data regardless of the machine
manufacturer. Development of the IIoT brings with
it new requirements to control, monitor and analyze
these massive amounts of data, and convert them
into actionable business intelligence in real time.
So, in addition to connecting machines with a
standard language, manufacturers need provisions
for local computing and secure networking.
Major networking equipment suppliers are
releasing hardware designed for long-term reli-
ability in data collection and security under factory
conditions. Advanced switches and other compo-
nents now enable manufacturers to collect data
for both local and cloud computing environments.
This provides a more customizable approach to
security, data storage and analysis.
Fortunately, the networking equipment offers
a high level of functionality and can withstand the
industrial environment. These devices include
CONTRIBUTOR JIM BROWN, Manager of Controls Sof t ware Development , Makino
36 MMS January 2017 mmsonline.com
network routers and switches that can be powered
by 24 volts of direct current and embedded into
an industrial equipment controller. They provide
the functionality necessary for secure data trans-
fer to and from the equipment. Some contain the
MTConnect agent, a software utility that facilitates
data collection in the specified format.
While most industrial equipment controllers are
equipped with Ethernet capability, these are simply
Ethernet ports with no data security or ability to
select which devices can connect to the port for
data transfer. To provide this capability, a network
“smart” switch must be installed. This switch is
smart in the sense that it can be programmed to
allow only authorized computers to connect for
data transfer with the device. It ensures the secu-
rity of data collected in the machine or device.
The growth of the IIoT has spurred a proliferation
of Ethernet devices used in machining centers and
other equipment on the factory floor. An Ethernet
port enables these devices to connect with the
machine controller via an Ethernet network. If an
industrial device is then connected to the factory
network, all of the Ethernet devices in the machine
must be assigned an Ethernet address, called an
IP address, on the factory network. The address
makes all these devices accessible from the com-
pany network and exposes them to potentially
heavy network traffic.
The solution to this problem is the use of a
factory-hardened Ethernet router. Such a router
allows definition of a network on the machine side
that is not exposed to the factory network. Selected
Makino’s ProNetConneX IIoT interface uses a Cisco
IE4000 industrial network switch to provide reliable
and secure connectivity to a shop’s network.
 ENHANCE
YOUR

ALUE
STREAM

Automated Resource Deployment

Real Time Remote Monitoring

Detailed Efficiency Reporting

Quick Setup and Simple Interface

info@smartattend.com www. .com (866) 210 - 9630

DECIDING FACTORS A Focus on Data-Driven Manufacturing
Ethernet addresses in the machines that need to
be exposed to the factory network can be pro-
grammed using a utility called Network Address
Translation (NAT). Using NAT, the Ethernet address
to be assigned on the factory network is translated
to an address programmed into the router. Similarly,
information sent from the Ethernet address pro-
grammed into the router is translated out to the
factory network. In this way, the Ethernet devices
used in the machine controller that do not require
connection to the factory network can be protected
from that factory network.
Manufacturers also will need IIoT solutions that
combine cloud-based computing with new forms
of computing to collect and analyze machine data
on the factory floor. In cloud computing, data is
collected and transmitted from the factory over
secure networks to servers in remote locations.
As IIoT solutions are implemented in more machines
and industrial processes, they generate vast
amounts of data that cannot be affordably trans-
38 MMS January 2017 mmsonline.com
mitted, stored or processed. The solution is inte-
grated computing, networking and storage closer
to the machines. This approach, becoming known
as fog computing, eliminates “latency,” the tendency
for data transmission and processing to slow down
as a result of the excessive volume of data. Fog
computing also dramatically reduces bandwidth,
the capacity of the network to transmit vast amounts
of machine data to the cloud. The security of a
shop’s machine data also is improved because
sensitive information and machine controls do not
have to be exposed to networks and storage devices
outside the shop’s systems.
The emergence of factory-hardened network
devices will enable manufacturers to gather, ana-
lyze and make business decisions based on insights
from the data on a much broader scale than ever
before. To ensure this digital transformation of
operations succeeds, manufacturers must consider
not just what can be done, but how to connect
their machines securely to the IIoT.
COMPETING IDEAS Columnist
Preparing an Effective
Job Interview
Filling an open position is a process that requires time and planning in order
to meet the end goal: finding the right person for the job.
One of the facts of business is that people
leave companies. Whether it’s a voluntary or
involuntary separation, a void is created that
usually, somehow must be filled. If we are fortu-
nate enough to be able to replace the person
leaving, we are faced with the prospect of inter-
viewing candidates, and unfortunately, this is
something most of us do not do well. Sometimes,
we are so anxious to replace an employee that
we don’t put enough time into the interviewing/
vetting process and hire the wrong person. Other
times, we hem and haw about the best candidate
for the position and delay making a decision to
the point of losing a highly qualified person to
another company or, even worse, a competitor.
Interviewing is a process, and like all processes,
there is always room for improvement. Prepara-
tion is essential to making the process more
effective and finding the right person for a job.
Here are some considerations when preparing
to conduct interviews for any open position:
1. Know the real needs of the job you are
filling. There are usually formal job descriptions
for every position, and sometimes they are even
up-to-date and reflective of the job requirements.
Even so, a general job description may not be
enough. Take some time to list the requirements
that you believe are really important to the posi-
WAYNE S. CHANESKI
EXECUTIVE DIRECTOR
CENTER FOR MANUFACTURING SYSTEMS
NEW JERSEY INSTITUTE OF TECHNOLOGY
40 MMS January 2017 mmsonline.com
tion you are filling. While still fresh in your mind,
you may want to consider all of the tasks the
prior employee did well, or not so well, and see
where they fit on your needs list. One of my clients
recently undertook this specific effort after an
employee left, and it changed his thinking about
the type of person he was looking for.
2. Rank the real needs in order of priority.
This helps separate the “must-have” needs from
the “would-like-to-have” needs. Although you
may think everything on your requirements list
is important, some needs are more important
than others. Be selective about what you must
have, as the fewer requirements you stipulate,
the more choices you will have to fill the position.
It does no good to have so many must-haves
that nobody can possibly qualify for the job.
3. Build interview questions around the
real needs. Exact interview questions will vary
depending on the job being filled, but the types
of questions can be surprisingly similar from job
to job. If the job is a management position and
one of the must-haves is leadership skill, think
of questions that will assess the candidate’s
experience acting as a leader. Such questions
usually begin with the phrase: “Can you give me
an example of . . . .” If the job is a technical posi-
tion and one of the must-haves is mechanical
aptitude, think of questions that will reveal how
that person performed in troubleshooting, or
building or repairing products. After the ques-
tions relating to these requirements are addressed,
develop questions that will reveal additional
information about the candidate’s skills and
experience. Often, this second phase of ques-
tioning will reveal subtle differences between
COMPETING IDEAS Columnist
candidates that may all possess the must-have
traits you are seeking.
4. Plan to talk less and listen more during
the actual interview. The candidate should do
most of the talking. Although an interview should
be a so-called two-way street in which the com-
pany learns about the candidate, and the can-
didate learns about the position and the company,
it is all too common for the interviewer to do most
of the talking. As someone once said: “Those
who are talking are not listening, nor learning.”
There should always be time allotted at the end
of the interview for the candidate to ask ques-
tions, and that is when the interviewer should
do most of the talking.
5. Consider using two interviewers. Tra-
ditionally, interviews are conducted on a one-
on-one basis. Although this can be effective, you
may be able to learn more about a candidate if
two people are asking questions during the
interview. The two interviewers can actually help
each other by asking questions from different
Mitutoyo America Corporation | 1-888-mitutoyo | www.mitutoyo.com
CMM • VISION • FORM AND FINISH
42 MMS January 2017 mmsonline.com
viewpoints. Some may argue that this puts the
candidate at a disadvantage and may even be
intimidating, but if a prospective employee cannot
handle the job interview, he or she is not likely
to do well in the job.
6. Plan on summarizing your perception
of how the candidate would perform in the
job. At the end of the interview, plan to tell the
candidate what impressed you about his or her
background and, although it may create some
discomfort, what you believe could be a problem
for the candidate if he or she were to get the job.
Consider this a sanity check of sorts. Unless you
have a great deal of interviewing experience and
a strong record of hiring success, there is a
chance you have missed or misinterpreted some-
thing during the interview. Providing the candidate
an opportunity to comment on your perception
could yield a win-win outcome in the event you
did miss or misunderstand something important.
It is also an opportunity to see how the candidate
reacts to criticism.
Precision is Our Profession
As the world’s leading metrology
company, Mitutoyo is committed to
break-through technologies in current
and future product development for its
full range of dimensional measurement
tools, instruments, software and systems.
Held in the belief that providing the
highest quality products and services to
our customers, in turn allows you to do
the same for your customers, Mitutoyo
continues to develop the most advanced
metrology solutions. “Precision is our
profession,” is not only the company
motto, but also the principle by which
every Mitutoyo employee stands.
Product Catalog
www.mitutoyo.com/cat
• PRECISION TOOLS AND INSTRUMENTS • DATA MA N AGEMENT
 MA-600HII

FAST, ACCURATE HORIZONTAL

MACHINING POWER
The MA-600HII provides the perfect balance of power and rigidity for the strength
needed to handle all your difficult-to-machine materials.

Contact your local Okuma distributor for details

or visit www.okuma.com/americas to learn more.

Arizona CNC Equipment GOSIGER HEMAQ Thomas Skinner & Son

www.arizonacnc.com www.gosiger.com www.hemaq.com www.thomasskinner.com

EMEC Machine Tools, Inc. Hartwig, Inc. Morris Group, Inc.

www.emecmt.com www.hartwiginc.com www.morrisgroupinc.com
THE VIEW FROM MY SHOP Guest Columnist
Keeping Up, One Small
Step at a Time
Incremental change is the secret to staying globally competitive in an industry
where everything seemingly is obsolete as soon as you buy it.
A s a m ac h i n e s h o p ow n e r, I h ave m a ny
demands on my attention.
Every day I’m bombarded by a ton of different
issues. Much of that impact comes from sales-
people or the media telling me all about a new
tool or a new state-of-the-art piece of equipment
that will revolutionize my business and skyrocket
my profits. Articles are being written about how
3D printing is the way of the future, but at the
same time, I can hear about a brand-new tech-
nology to make machining better than ever and
also read a grim prediction for the industry’s
ultimate fate.
This constant stream of conflicting information
is tearing apart my brain cells. I often wonder
why I didn’t just become a plumber. My life would
have been much simpler. All I would need is a
wrench, right?
Over the past 30 years, I have come to believe
that machining is the most capital-intensive
industry out there. It can seem as though every-
thing we buy for our shops soon becomes obso-
lete. We only have to take a look at the hundreds
of orphan tools in our tool cribs to know that’s the
truth. But we tend to keep all of them, just in case
that one job on which we used that particular tool
comes back around again 17 years later.
So how do we keep our shops competitive?
This Month’s Columnist:
UDO JAHN
GENERAL MANAGER
MODERN ENGINEERING
DELTA, BRITISH COLUMBIA
UDO@MODERNENG.COM
44 MMS January 2017 mmsonline.com
Part of that constant stream of conflicting
information introduces us to new equipment that
can completely change the game, so to speak,
for our individual shops. This is what happened
when multi-axis machines with automated han-
dling systems first came out. A lot has changed
since then. Trying to stay competitive today with
three-axis machining centers or two-axis lathes
is like a new printer opening up shop armed with
only the original Gutenberg printing press. Try
taking on Kinkos with that.
It’s not enough to just have modern machin-
ery, however. Shops also need to stay current
with software in order to run competitively. CAD/
CAM, enterprise resource planning, material
requirements planning—over time, our machine
shops could begin to resemble mini NASA mis-
sion control centers, with employees attached
to little screens, monitoring every aspect of the
business from equipment to people to profit and
productivity, seemingly all calculated down to
the nanosecond. Somewhat creepy.
Why would anyone put themselves through
this non-stop merry-go-round of investments in
order to stay current and competitive? When the
pace of our industry becomes overwhelming,
stop the merry-go-round, take a deep breath,
and think.
The ultimate goal of every machine shop is to
be globally competitive. It’s hard to put a finger
on exactly what that means, however, because
what’s competitive today may not be tomorrow.
It’s a goal that’s always in forward motion.
Machining has become a lot more complicated
over the past century, and even the last decade.
If we allow it to, the number of innovations and
THE VIEW FROM MY SHOP Guest Columnist

amount of information out there could overwhelm
us. What should we do when we can’t possibly
do everything? The key is to do something.
So many shops choose to just do nothing and
then get so far behind in remaining competitive
that they can never catch up. Competitiveness
may look like a mountain that needs to be climbed
right away, but focusing on making small changes
in our businesses daily or weekly will get us to
the top of the mountain eventually.
Begin by developing an improvement plan
that will make your shop a little bit better every
day. To start, figure out what equipment you will
need to be more competitive in the future, not
just today. If you buy for today, you will be
frustrated tomorrow.
You can also start standardizing your tooling
from good suppliers. This will help make your
machining more predictable. You should only
change to other tooling if you determine that it
fits your shop and benefits most of the shop’s
machining processes.
Next, look for ways to streamline programming
and scheduling. Always think simple. Simple
means faster, which means more productive.
Try to streamline and simplify every day.
When we focus on becoming incrementally
better, just a little bit each day, we will reach our
goals, slowly but surely. Be consistent, and
results will follow.
I’m trying to do this, too. With the lowered
stress level of focusing on small, daily improve-
ments instead of a mega-mountain of them all
at once, I have a happier outlook for the future
of machining. I think I’ll give up on the idea of
being a plumber. After all, then I’d have to change
my tooling.
Modern Engineering, a Vancouver-area
contract machine shop, is one of the larger
five-axis machining providers on Canada’s
west coast. More at moderneng.com.

HAIMER
Power Mill
Maximum metal removal
rate – A quantum leap into
the next milling dimension.

Variable helix design for vibration-free machining

<0.0002” runout accuracy for ultimate precision
Fine-balanced for consistent and repeatable
performance
Integrated Safe-LockTM shank – for optional
use with Safe-LockTM tool holding technology

Tooling Technology
Shrinking Technology Balancing Technology Measuring Instruments

Haimer USA, LLC | 134 E. Hill Street | Villa Park, IL 60181 | Phone: +1-630-833-1500 | Email: haimer@haimer-usa.com | www.haimer-usa.com

46 MMS January 2017 mmsonline.com

SHOP TALK
SORALUCE TECHNOLOGY DAYS
HIGHLIGHTS MULTITASKING,
AUTOMATION AND PRODUCTIVITY
BY STEPHANIE HENDRIXSON
Machine tool builder Bimatec Soraluce, part of
the Danobat Group, welcomed more than 800
European, American and Asian customers to its
Technology Days celebration November 14-18.
Soraluce is a manufacturer of large milling, turning
and boring machine tools, with work envelopes
ranging to 8 meters high and 90 meters long.
Custom and turnkey solutions are among the
company’s specialties. Its primary markets are
Germany and Italy, but its machines are used
around the world for large-part machining appli-
cations such as oil and gas equipment, industrial
vehicle engine blocks, and tool and die work.
Though Soraluce is headquartered and man-
ufactures its products exclusively in Spain, its
annual customer Technology Days event takes
place at the company’s Center of Excellence in
Limburg, Germany. Renovated in 2012, the build-
ing boasts 2,500 square meters of showroom and
machine demonstration space plus offices and a
48 MMS January 2017 mmsonline.com
service center. The 2016 Technology Days cel-
ebrated the 25th anniversary of this location,
established in 1992.
In addition to observing this milestone and
honoring key employees and customers, Soraluce
used the event to unveil new technology and
emphasize three core themes: multitasking,
automation and productivity.
1. Multitasking. Soraluce specializes in large
gantry-type machine tools for milling, boring and
turning of large parts, with its smallest model
accommodating workpieces 1.8 meters tall and
the largest 8 meters. The company offers dedi-
cated multitasking machines as well as those that
can be equipped for multitasking. The TA-M 20
milling machine launched at Technology Days,
for example, is also equipped for turning work
with a rotary table and a device that enables the
spindle to be clamped in place for stability.
2. Automation. While there were no robotic
Smart Machine,
Soraluce’s Industry 4.0
solution for machine
monitoring and data
reporting, was one of the
most popular displays.
The monitor at the event
displayed real-time data
from a machine tool at
the company’s facility in
Spain, as well as from
an FL 8000 floor-type
milling-boring center
located just around the
corner inside the Limburg
Center of Excellence.
SHOP TALK

arms or palletized cells on display at the Center Certain machine functions also incorporate
of Excellence, Soraluce does offer automated automation. For example, a new Dyanamic Active
solutions, and its machine tools have features to Stabilizer (DAS) system monitors and corrects for
support this. The FP 10000 floor-type milling- vibration generated during milling. As Mr. Gon-
boring center shown at Technology Days, for zalez says, there is “no magic fixturing solution”
example, has an open architecture that could to solve chatter. So, rather than try to eliminate
easily accommodate pallet changers, a robot and chatter mechanically, DAS automatically adjusts
tool arena, or other automation, says David Gon- for detected vibration by applying a counterforce.
zalez, sales director. 3. Productivit y. Soraluce demonstrated
innovations to improve
productivity and profit-
a b i l i t y, a n u m b e r o f
which related to
machine maintenance.
The company’s change-
able heads, for instance,
could be used as spare
s p ind l e s in th e c a s e
of a machine crash to
keep the machine tool
up and running.
Another is Smar t
M achine, Soraluc e’s
answer to Industry 4.0.
This machine monitor-
ing system tracks
machine data related to
axis position, vibration,
ambient temperature,
coola nt te mpe rature
and pressure, alarms,
and more, and gener-
ates reports on energy
consumption, tool uti-
lization and other key
metrics. The system can
monitor multiple
machines, even those
in dif ferent locations.
Fo r exa m p l e, d u r i n g
Te c h n o l o g y D a y s , a
demonstration Smar t
Machine display showed
data for two machine
tools: one in the Limburg
center and a second in
the company’s Bergara,
Spain, headquar ters.
I n a d d i t i o n to b e i n g

50 MMS January 2017 mmsonline.com

www.smtcl-americas.com | https://store.smtcl-americas.com
info@smtcl-americas.com | +1 626.667.1192
SHOP TALK

accessible to the customer via desktop computer NIMS SELECTED BY

or tablet, collected data is also reported back to U.S. DEPARTMENT OF LABOR
Soraluce via the cloud for diagnostic and preven- TO EXPAND REGISTERED
tive maintenance purposes. APPRENTICESHIP PROGRAMS
To see and learn more from the Soraluce Tech- The National Institute for Metalworking Skills
nology Days, view my unabridged report and (NIMS; Fairfax, Virginia), the manufacturing indus-
slideshow at short.mmsonline.com/soraluce. try’s developer of skills standards and credentials,
Soraluce, call 815-315-9261 has been selected by the United States Depart-
or visit soraluce-america.com. ment of Labor as an industry intermediary to
support the expansion
of registered apprentice-
ships within manufactur-
ing. NIMS will work with
Having issues with your
finishing process? industry, workforce and
Send us your parts and we’ll help education partners to
you find a better process.
incre ase acce ss to
apprenticeships and

Superior Finish
assist employers in
developing new pro-

Superior Durability grams that reach diverse

talent pools. As part of
Rosler is the global leader in supplying tailor-made finishing solutions for the this initiative, $500,000
automotive industry. Our mass finishing and shot blasting systems provide is available to support
precise, repeatable processes with a low cost per piece and short process times. companies in establish-
ing a registered appren-
ticeship program with
the Department of Labor.
“This contract gives
us the unique opportu-
n i t y to c r e a t e m o r e
impact in our industry
by expanding appren-
ticeships to underrep-
resented populations
and to new companies
Rosler’s line of rotary barrel RMT shot blast machines looking to establish a
are ideal for processing a wide variety of small to sustainable talent pipe-
medium sized automotive stampings and castings. line,” says E xecutive
Director Jim Wall.
NIMS will focus on
providing companies

finding a better way... with tools and resources

to develop customized
registered apprentice-
Rosler Metal Finishing USA is the leader in mass finishing, shot blasting, ship programs. These
automated processes and media - made in the USA.
programs combine on-
Visit www.rosler.us or call 269-441-3000 for more information.
the-job training with job-
related classroom
instruction and meet

52 MMS January 2017 mmsonline.com

 INCREASE
PROFITABILITY
from Your Machining Operations
With Custom Built Equipment for
Processing Scrap Metal and Spent Fluids

Turnings & Chip Dualpak™ Coolant Recycling

Processing Systems Chip Briquetters Systems

OPTIMIZE IMPROVE CUT

Container Loading Plant Safety New Coolant Purchases
and Tool Life and Haul Away Costs

Designed for you – guaranteed.

65
YEARS

Made in the USA

See how to reduce your costs: prab.com/scrap-fluid-mgmt

Contact us at sales@prab.com • 1.800.968.7722

SHOP TALK

national standards for registration with the Depart-
ment of Labor or State Apprenticeship Agencies.
Major stakeholders that will suppor t the
expansion of apprenticeships in manufacturing
include AMT—The Association For Manufactur-
ing Technology, the National Tooling and Machin-
ing Association (NTMA), the Precision Machined
Products Association (PMPA), and several other
associations, organizations and institutions.
NIMS is seeking companies and education
and industr y par tners that are interested in
enhancing their talent pipelines through appren-
ticeships. For more information on building an
apprenticeship program or partnering with NIMS,
visit mfgapprenticeship.com or email the NIMS
Apprenticeship USA team at apprenticeship@
nims-skills.org.
NIMS, call 703-352-4971 or visit nims-skills.org.

SMARTCAMCNC,
MODULEWORKS
ANNOUNCE
LICENSING
AGREEMENT
SmartCAMcnc, devel-
oper of the SmartCAM
software suite for CNC
programming, has made
a licensing agreement
with ModuleWorks for
the integration of the lat-
ter’s simulation technol-
o g y m o d u l e i nto th e
former’s CAM software
products, specifically
SmartCAM v2017. Mod-
Celebrating Eight Decades of Excellence uleWorks’ stock removal,
error detection, toolpath
in Carbide Cutting Tool Solutions analysis and backplot-
ting technology replaces
Smar tCAM’s curre nt
verification tools.
“Customers will
i m m e d i a te l y b e n e f i t
from the new, integrated
ModuleWorks material
removal verification
Cole Carbide celebrates 80 years of excellence as a leading provider of cutting e n g i n e ,” s a y s D o u g
tool solutions and systems. Four generations of the Cole family have carried
Oliver, SmartCAMcnc’s
Cole Carbide’s vision, serving clients with a commitment to family values,
product innovation and quality assurance. Today, Cole continues to impress,
senior product manager.
expanding their reach as a globally integrated, locally serving company that ModuleWorks GmbH,
satisfies diverse needs. From John Cole and the rest of the Cole “family” we call 49 241 990004-0
thank you and look forward to serving you in the years to come. or visit
moduleworks.com.
Cole Carbide Industries, Inc. World Headquarters SmartCAMcnc,
4930 S. Lapeer Rd. • Orion Twp., MI 48359 • U.S.A. call 541-344-4563
Tel: 586.757.8700 • Fax: 586-757-8701 • www.colecarbide.com or visit
smartcamcnc.com.

54 MMS January 2017 mmsonline.com

 UP TO 50% OFF SELECT LATHES! LIMITED TO STOCK ON HAND!

18" x 40" Electronic Variable-Speed Lathe w/DRO

SPECIFICATIONS: INCREDIBLE SPECIAL!
• Swing over bed: 18.11"
• Spindle bore: 3.1" SB1059F
• Distance between centers: 40"
• Spindle speeds: (EVS), 18 – 1800 RPM
$41,500
• Spindle motor: 10 HP, TEFC induction
$
21,995
• Voltage/phase: 220V, 3-phase PLUS FREIGHT
• Machine footprint: 713∕4" x 1021∕2"
• Approximate shipping weight: 5080 lbs.
IN STOCK!

14" x 40" Electronic Variable Speed Lathe 16" x 60" Electronic Variable-Speed Lathe
with DRO

SB1013 SB1015F
REG. $21,295 REG. $26,895
SALE 13,500
$
SALE $18,500
PLUS FREIGHT PLUS FREIGHT

18" x 60" Turn-Nado Gearhead Lathe 18" x 80" 16-Speed Gearhead Lathe
with DRO with DRO

SB1057F SB1058F
REG. $34,500 REG. $38,500
SALE $24,995 SALE $22,995
PLUS FREIGHT PLUS FREIGHT

18" x 60" Electronic Variable-Speed Lathe 18" x 80" Electronic Variable-Speed Lathe
with DRO with DRO

SB1060PF SB1061PF
REG. $44,500 REG. $47,500
SALE 26,995
$
SALE $28,950
PLUS FREIGHT PLUS FREIGHT

Hundreds of Thousands of Lathes Sold Since 1906

18536

Visit our Website for a Full Selection of Metalworking Machinery & Accessories
southbendlathe.com® • (360) 734-1540 • sales@southbendlathe.com
SHOP TALK

SIEMENS, STRATASYS fulfill their shared vision of incorporating additive

FORM PARTNERSHIP TO manufacturing into the traditional manufacturing
INCORPORATE AM INTO workflow, helping it to become a universally rec-
TRADITIONAL PRODUCTION ognized production practice that can benefit
Stratasys Ltd. and Siemens have announced a multiple industries, including aerospace, automo-
formal partnership to integrate Siemens’ Digital tive, transportation, energy and industrial tooling.
Factory solutions with Stratasys’ additive manu- This announcement also builds on Siemens’
facturing solutions. The partnership is intended recently announced end-to-end solution integrat-
to lay the foundation for the two companies to ing digital design, simulation and data management
with conventional and
additive manufacturing.
The two companies
have already been col-
laborating on multiple
projects, including the
direct link from Siemens’
Tailored To Fit NX software for CAD/
CAM/CAE to Stratasys’
GrabCAD Print platform,
enabling a seamless
design-to-3D print work-
flow, and the recently
prev iewe d S tratasys
Robotic Composite 3D
Demonstrator, which
incorporates Siemens’
product lifecycle man-
agement (PLM) software
and its motion control

SharpVue
and CNC automation
technologies to produce
strong, lightweight per-
Advanced Digital Microscopy formance parts.
Item # 26700-135
In their joint press
release, the companies
argue that while additive
Sophisticated, Versatile and User-Friendly manufacturing technol-
• Crystal-clear image with true color reproduction o g y h a s m ad e g re at
• Rapid auto-focus lens strides over the past
• Built-in LED lighting
years, additional criteria
• 9” working distance
• USB and HDMI outputs are required for it to take
• 30x Optical Magnification, 300x Digital its place in volume pro-
• Includes remote control with clearly labeled duction environments
buttons and become as com-
• Imaging and measurement software included.
monplace as CNC. Ide-
SharpVue 360° Tilt Table SharpVue X-Y Glide Stage ally, the companies say,
Item # 26700-135-TTB Item # 26700-135-XYTB
additive manufacturing
solutions should deliver
aveninc.com | 734-973-0099 | sales@aveninc.com
robust, repeatable and

56 MMS January 2017 mmsonline.com

 NEW
CERATIZIT 3x3
STEEL TURNING
SOLUTIONS
THE PERFECT COMBINATION
If you’re turning steel, your life just got a lot easier. With the
CERATIZIT 3x3 portfolio, just three chip grooves and three
versatile carbide grades combine to handle all levels of steel
turning – roughing, finishing and everything in between.
Optimized chip grooves for roughing, medium/universal
machining, finishing
Economical, less inventory, higher productivity
Enhanced stability, less power, longer tool life
All-purpose use, high reliability and high performance
Cutting Solutions by CERATIZIT. We do more thorough
engineering upfront so you get optimum results where it counts.
Find out more at ceratizitusa.com.

To view the catalog, PowerPoint and video,

visit ceratizitpromos.com/3x3 or scan the QR code.

CERATIZIT USA, Inc.

1 800 783 2280 1 586 759 2280 ceratizit.com
Info.usa@ceratizit.com
SHOP TALK

reliable operational performance with predictable large-scale manufacturers to take advantage of

properties across a broad portfolio of materials additive manufacturing in traditional production
that are certifiable for specific applications and environments, with the aerospace, automotive
that are driven by a seamless, digital integration and tooling industries expected to benefit first.
from design to production. Together, Stratasys Siemens Digital Factory, call 800-879-8079
and Siemens plan to address these challenges. or visit plm.automation.siemens.com.
Dan Yalon, executive vice president of products Stratasys Inc., call 888-480-3548
for Stratasys, says that the technology coming or visit stratasys.com.
out of this par tnership is intended to enable
KITAGAWA-
NORTHTECH
HIRES SENIOR
MANAGER,
ENGINEERING
AND QUALITY
Kitagawa NorthTech Inc.
(Schaumburg, Illinois)
has named Ed Johan-
nesen senior manager
of engineering and qual-
i t y. H e w ill h e ad th e
design engineering
group and quality control
and lead continuous
improvement processes
for the company.
Kitagawa-NorthTech
Inc., call 800-222-4138
or visit kitagawa.com.

CORRECTION:
FOOEY ON FOOE
In last month’s Deciding
Factors column, “OEE
May Not Be Enough,”
we failed to catch two
instances of the incor-
rect acronym “FOOE.”
Lest there be any confu-
sion, the correct acro-
nym for “financial over-
all equipment efficiency”
is “FOEE,” not “FOOE,”
which more closely
resembles an expletive
generally reserved for
such events as an unex-
pected spindle crash or
stubbed toe.

58 MMS January 2017 mmsonline.com

 “We grind flute faces to 0.2
Ra with the MX Linear”
-Joe Adams, plant manager, Myles Tool, Sanborn, NY

A multi-million-dollar company, Myles Tool relies on 7

ANCA MX tool CNC tool grinders to produce its standard
and special carbide cutting tools.

Their new MX7 Linear CNC tool grinder includes ANCA’s

patent pending LinX Linear Motors, which deliver smooth
axis movement, resulting in significant improvements to
surface finish.

ANCA offers 2 models in the MX
Linear range. Find out more at
www.anca.com.
No separate chiller unit is needed for the linear
motors, saving cost and floor space.
Automation and wheel changer options contribute
to maximum efficiency.

www.anca.com info@anca.com
MEETING
MEETING DATES
DATES

MARCH 22-25 APRIL 25-27

Fernandina Beach, Florida Columbus, Ohio
themfgmeeting.com pmts.com

The MFG Meeting offers a comprehensive agenda
covering everything from manufacturing sales
and marketing strategies to economic forecasts
and industry trends. The event is hosted by AMT—
The Association For Manufacturing Technology
and the National Tooling and Machining Associa-
tion (NTMA).
Presented by the Precision Machined Products
Association (PMPA), and co-presented by Modern
Machine Shop and its sister publication, Produc-
tion Machining, PMTS is dedicated to the precision
machining industry in North America. More than
280 exhibitors will display equipment, products
and services to more than 6,000 attendees.
 MEETING DATES

February 22-23 | Texas Design-2-Part Show April 23-25 | PMPA National Technical
Grapevine, Texas Conference
d2p.com Columbus, Ohio
pmpa.org
March 3-5 | PMPA Management Update
Conference April 25-27 | Parts Cleaning Conference
Nashville, Tennessee Columbus, Ohio
pmpa.org pmts.com

March 6-9 | AeroDef May 2-4 | MT360

Fort Worth, Texas Nashville, Tennessee
aerodefevent.com amtonline.org/calendar/mt360.htm

March 7-12 | TIMTOS June 14-15 | Amerimold

Taipei City, Taiwan Rosemont, Illinois
timtos.com.tw amerimoldexpo.com

March 29-30 | Southeast Design-2-Part Show June 20-22 | Rapid.Tech

Atlanta, Georgia Erfurt, Germany
d2p.com rapidtech.de
QUALITY GAGING TIPS Columnist
Looseness—An Enemy of
Precision
When a gage isn’t coming up with accurate measurements, the culprit could
be a connection that simply isn’t tight enough.
There are a couple of professional football
teams out there who are leading their divisions
and whose main driving principles include main-
taining a focus on the fundamentals in order for
their players to do their best. This same principle
can be applied in gaging: Going over the simple
basics—sometimes again and again—will enable
us in the dimensional measurement world to
achieve championship-level results.
In recent columns, we’ve discussed several
enemies of precision gaging, including dirt, force
and wear. Another that is frequently overlooked
in situations where a gage does not repeat or
calibrate properly is looseness.
Because I’ve seen the effect of looseness on
precision measurement so many times, one of
the first things I look for when there are problems
is a loose contact point. The indicator point
should not be tightened with pliers so hard that
the screw threads swell the end of the rack or
undue rotation of the rack damages the anti-
rotation pins. It should, nevertheless, be a little
more than just finger-tightened.
The photo on page 64 shows a typical bench
stand gage. We have highlighted places on the
gage where looseness can cause problems.
When troubleshooting a gage that isn’t coming
up with the right measurement, check that all
GEORGE SCHUETZ
DIRECTOR OF PRECISION GAGES
MAHR FEDERAL INC.
62 MMS January 2017 mmsonline.com
the screws, nuts, bolts and connections are
socked up tight. One loose spring on a panto-
graph-style transfer device will be hard to detect,
but until it is corrected, you can be sure the gage
will produce inaccurate results.
Looseness is not necessarily associated only
with mechanical joints. It can also show up in
the form of a shoddy solder, or a bad connection
in a cable or connector that can make the gage
completely unusable at times. And I can’t tell
you how many times something as simple as a
loose hose connector in an air gage causes a
very tiny leak that can introduce noise or even
put the whole gage off scale.
A related enemy that is often overlooked with
adjustable bore gages is centralizer pressure. If
centralizer pressure is too light or uneven, the
gage’s reference and sensitive contacts may not
get centered on the true diameter of the part
bore. The user who is relying on the centralizer
will find himself measuring the chord of the circle
instead of the full diameter. On the other hand,
if the centralizer pressure is too high, the central-
izer contact can burnish or even scratch the
surface of the bore, not to mention also cause
excessive wear to the contacts.
The amount of centralizer pressure designed
into a gage depends on the weight of the gage—
specifically, on how much of the gage’s weight or
drag the centralizer has to move. For example,
consider measuring the inner diameter of a bore
with the typical adjustable bore gage while the
workpiece is in the spindle of the machine tool.
In this case, the gage would be horizontal, the
centralizer would be vertical, and the weight of
the gage would be supported on the reference
THE

Manufacturing for Growth

MARCH 22–25, 2017 • AMELIA ISLAND, FLORIDA
Tailored to the needs of manufacturing’s current and future leaders, The MFG
Meeting will help you gain a deeper understanding of issues ranging from
new technologies to economic indicators to cultivating your workforce. And
you’ll be gaining this insight alongside hundreds of executive- and senior-level
peers, giving you an unparalleled opportunity for growing your professional
network and sharing best practices.

R E G I S T E R T O D AY AT
TheMFGmeeting.com
QUALITY GAGING TIPS Columnist

contact (the one pointing down). But suppose the

operator turns the gage sideways (because that’s
All screws on fine
what operators like to do). Now the weight of the adjustment mechanism
gage is no longer supported by the reference Arm locked to post tight (fine adjustment
screw locked)
contact. The centralizer spring must not only
support the weight of the gage head, but in cen-
tralizer fashion, must basically pull the gaging
Back screws tight
head up against gravity into the center of the bore. (indicator square to
For some gages, especially those set up for larger base)
diameters, this can amount to a lot of weight and Contact point light
require some pretty hefty gaging force.
The bad news/good news here is that while
gages get heavier with increased bore size, Platen secure
Post tight to base
chordal error gets smaller with increased bore and square
size. So there is some balance. However, in the
case of smaller bores—especially those smaller
than a couple of inches—bad centralization
caused by improper gaging pressure can be a
serious enemy to precision.
Clearly, looseness and improper pressure are When troubleshooting a gage that isn’t coming up
both enemies any championship-seeking team with the right measurement, check that all the screws,
can do without. nuts, bolts and connections are socked up tight.

64 MMS January 2017 mmsonline.com

CNC TECH TALK Columnist
Conflicting CNC Applications
Almost every critical feature can be used in multiple ways. Be aware of the options,
and choose those that are most appropriate for your specific applications.
As CNC application has evolved over the years,
CNC providers have developed a variety of ways
that certain CNC features can be utilized. Indeed,
almost every critical CNC feature can be put to
use in multiple ways, and misapplications can lead
to under-utilization of CNC machine tools. In some
cases, usage methods even conflict with one
another, meaning a usage method that works nicely
for one company will not be appropriate for another.
In order to make the best use of your specific CNCs,
you must know your options. Then, you must
choose the usage options that are appropriate to
your particular company. Here are some common
examples of such CNC options, along with a few
suggestions for use.
Conventional (offline-programmed) vs.
conversational (shop-floor-programmed).
This programming decision should be based on
three factors: lot size, repeat business and program
cycle time. For shops that handle many repeated
jobs, large lots and lengthy cycle times, conventional
CNCs are the better choice, as there is ample time
to prepare programs before they are needed on a
machine. When it comes time to run (or rerun) a
job, the required program will be ready, and some
form of distributive numerical control (DNC) system
can be used to quickly transfer it to the CNC.
Conversely, shops that consistently run small
lots of new jobs with short cycle times often find it
impossible to keep up with the number of required
programs. Programs are almost always created
MIKE LYNCH
FOUNDER AND PRESIDENT
CNC CONCEPTS INC.
66 MMS January 2017 mmsonline.com
while the machine is down between jobs. In these
situations, conversational CNCs programmed on
the shop floor often shorten programming time
and eliminate the need to transfer programs.
Cutter compensation offset specification
(cutter diameter vs. cutter radius). With newer
CNCs, this selection is a parameter setting. Older
CNCs offer no choice, so you will be stuck with the
method provided by the CNC manufacturer. If you
have both older and newer machines, it may be
better to maintain consistency and select the
method used by the older machines for the newer
ones. Otherwise, this decision should be based
on how much sizing your setup people and oper-
ators perform with cutter compensation.
For the initial entry, and if the work surface path
is programmed, specifying the cutter diameter is
much easier than specifying the radius. If a cutter
is 1 inch in diameter, the initial offset entry will be
1.0 (using the imperial measurement system). With
radius measurement, the initial entry will be half
the cutter diameter. If the initial setting is the only
consideration, choose diameter entry. However,
sizing adjustments are more difficult with diameter
entry, since the adjustment amount must be dou-
bled each time. If 0.001 inch more material must
be removed from a workpiece surface, for instance,
the adjustment amount will be -0.002 inch. With
radius entry, the adjustment amount will match the
amount of material that must be removed from the
workpiece surface (-0.001 inch for this example).
Cutter compensation offset specification
(cutter size vs. deviation from planned size).
This decision is based on whether a CAM system
is used to create programs, as well as whether the
“planned” cutter size is used. If the programmer
specifies the work surface path, the initial offset
setting will be the cutter size (radius or diameter).
If the programmer specifies the cutter’s center line
 APRIL 25 –27, 2017
REGISTER TODAY!
Greater Columbus Convention Center | Columbus, OH USA

.COM
PM T S

PRESENTED BY: CO-PRESENTED BY: CO-LOCATED WITH:

CNC TECH TALK Columnist
path, and if the planned cutter size is used, the
initial offset setting will be zero. CAM systems can
generate either cutter center line path or work
surface path; it is simply the programmer’s choice.
On the other hand, manual programmers writ-
ing with G code usually find it more difficult to
program the cutter’s center line path and tend to
program work surface path instead. Since the
initial adjustment is easier when programming the
center line path (zero, if the planned cutter size is
used), this is our recommended method if a CAM
system is used to create the CNC program. Sizing
adjustments are done in the same manner regard-
less of which programming method is chosen.
Tool-length compensation offset specifi-
cation (cutting tool length vs. distance from
tooltip to Z-axis program zero surface). This
decision is based on lot sizes, cycle times, how
often the same cutting tools are used from job to
job and the availability of support personnel. The
more time there is during one job to get ready for
the next job, the more important it is to use the
DEBURR
ANY
CROSSHOLE
www.jwdone.com
68 MMS January 2017 mmsonline.com
cutting tool’s length as the offset value.
The tool length is the distance from the tooltip
to the spindle nose, a positive value. This length
can be measured either on the machine or offline,
it will remain consistent from one job to the next,
and it will even remain consistent among multiple
machines. For these reasons, we recommend
using the cutting tool’s length as the tool-length
compensation offset value. With this method, the
Z-axis program zero assignment value, the work
coordinate system offset Z register value, will be
the distance from the spindle nose to the Z-axis
program zero surface (a large, negative value).
Even if there is limited preparation time and
cutting tool lengths must be measured during
setup, it is just as easy to measure a cutting tool’s
length on the machine as it is to measure the dis-
tance from the tooltip to the Z-axis program zero
surface. If cutting tools are often used from job to
job, using the cutting tool length as the tool-length
compensation offset value will save the duplicated
effort required for measuring.
FEATURE

70 MMS January 2017 mmsonline.com


No Part Left Behind
The right mindset, the right five-axis technology and an intuitive approach to
palletization help this mold shop extend automated control to the majority of
its high-mix work.
BY MAT T DANFORD
T he worktable on Omega Plastics’ newest,
most sophisticated machining center doesn’t
have T slots. It doesn’t need them.
From EDM electrodes to mold cavities to the
simplest assembly items, virtually every part
machined for the company’s plastic injection
molds travels from workstation to workstation on
a pallet with pre-established work coordinates
that eliminate the need to re-indicate. At first,
such a system might not seem all that unusual—
at least not until one of the shop’s larger, 200-odd-
pound mold base blocks is brought into the
workzone on one of the same kinds of pallets for
complete, single-setup machining. At this point,
Omega’s thinking becomes clear: The automated
production process in place at this 70,000-square-
foot, 75-employee facility is not only reliable
enough, but also comprehensive enough that the
pallet receiver is the only inter face the new
machine’s worktable will ever require.
Putting together the three-machine robotic
cell at the center of this Clinton Township,
Michigan, shop’s production strategy required
p u s h i n g te c h n o l o g y b e yo n d of f-t h e - s h e l f
capability, says Ken Arbic, mold engineering
manager. Accommodating heavier steel required
modifications to both machine and tooling, with
the lat ter resulting in fix turing so precisely
repeatable that some parts can even be removed
from and returned to their pallets (or another of
Shop personnels’ own ingenuity was critical to
automating more than electrode machining and ram
EDM. Photo by Jerry Heckendorn of Omega Plastics.
FEATURE
the same style) without losing references.
As was the case with implementing automated
control in the first place, expanding it to cover
the majority of a highly varied, low-volume part
mix also required a strong foundation in what
many modern mold manufacturers consider a
key guiding philosophy. “Everything we do is
about achieving a predictable result,” explains
Jerry Heckendorn, business development man-
ager. “Whatever the result, we can work with it
as long as it’s repeatable.”
PROCESS TAKES PRECEDENCE
The basic idea is to eliminate the variability asso-
ciated with the artisanship that defined traditional
moldmaking. That means process must take
precedence on every job. Specifically, a standard-
ized, cut-to-the-CAD-model process, one that’s
developed in advance and that leverages evidence-
based practices, parameters and strategies to
ensure consistent quality from tool to tool.
Of course, buying into a philosophy is one
thing; living it is another. Among the best ways to
make a process predictable—to reduce the impact
of natural, human-induced variation—is to imple-
ment robotics. However, automation can be
difficult in an environment like a mold shop where
every part is different.
For Omega, that’s arguably even more so.
The company was founded in 1984 by Tom
Kaczperski, who saw an opportunity to provide
quick-turnaround, prototype bridge tooling for
customers ranging from entrepreneurs to Fortune
100 medical firms. The company has since
mmsonline.com January 2017 MMS 71
FEATURE
Omega’s System 3R Workmaster carousel robot loads
a pallet-mounted, pre-referenced electrode into a
Mitsubishi EA-12V ram EDM unit. The workpiece
on the table interfaces with the System 3R fixturing
system via a custom sub-pallet.
expanded its stable of “a la carte” services to
include low- to mid-volume production tools,
components, molding and assemblies, but high-
end prototyping/development and bridge tools
still constitute the bulk of the approximately 450
molds produced annually at Omega, Mr. Heck-
endorn says. Complex by prototyping standards,
this tooling produces plastic parts to final spec-
ifications, but only a few at a time at most, whereas
the more feature-rich production mold might churn
out 30, 60 or even upwards of 100 parts per cycle.
Such low-cavity work provides little opportunity
to machine parts in any significant volume.
One exception to that rule is perhaps the most
obvious target for automation at any mold shop:
graphite EDM electrodes (Omega produces about
40 per day). Given the labor involved with swap-
ping these components in and out of the tool-
changer, the shop’s ram EDM was the first to be
integrated with a Workmaster carousel robot
purchased from System 3R (a division of GF
Machining Solutions) in 2003. Next came a three-
axis graphite-machining mill that, once integrated
with the robot, could keep the EDM fed with
72 MMS January 2017 mmsonline.com
enough electrodes for an entire weekend of
completely unattended production. Before long,
Omega was taking on additional electrode work
from other shops rather than outsourcing its own.
However, the team still wasn’t satisfied. As far
as Mr. Arbic and Mr. Heckendorn are concerned,
efforts to integrate another machining center for
metalcutting set the shop apart from many others
with a similar manufacturing philosophy.
EVERYTHING ON A PALLET
Today, the robotic cell contains a Mitsubishi EA-12V
ram EDM from MC Machinery Systems, a Makino
V56 three-axis machining center outfitted for
cutting graphite, and a five-axis G350 universal
machining center from Grob Systems that cuts
tool steel and aluminum. The common interface
linking these three machines is modular tooling
from System 3R, which consists of drawbar-linked
chucks and pallets that provide repeatable, three-
point referencing to within ±0.002 mm. That’s
more than sufficient to shuttle pallets from machine
to machine without re-indicating the work at each
station, Mr. Arbic says.
However, this strategy proved easier to imple-
ment for the EDM and graphite-cutting machines
than for the metalcutting mill. For one, the inter-
face between workpiece and pallet wasn’t as rigid
as the vises and magnets the shop used previously
for milling operations. In addition, EDM operations
 FEATURE

All parts are modeled in CAD/CAM software along

with representations of the pallet, and all references
are calculated according to the geometry of a custom
tooling ball. In this case, Omega is making the most
of its material by machining multiple gibs (com-
ponents for mold slide assemblies) from the same
block. The pallet shown here is a 54-mm model from
System 3R.

tend to occur at the end of the process, he explains.

That is, parts emerge from the machine complete,
and electrodes stay on their pallets throughout
their entire lifetimes. In contrast, work slated for
the metal mill often has to be sent outside the
shop for heat treatment first, and it is more likely
to experience mid-stream engineering changes.
Even with sufficient rigidity, that meant taking
parts off their pallets and losing all offsets in the
process, but no longer. Now, the reference system
for any CAM program is intact as soon as the part
is mounted on a pallet. In addition to heat-treat
and engineering-change situations, this capabil-
ity is particularly useful for emergency repair or
replacement work. “We can put damaged parts
back on pallets with intact references, and we
can also make new inserts from original CAD files
with very high confidence that they’ll fit,” Mr.
Heckendorn says. How is this possible? The shop
has developed its own, proprietary referencing
scheme and taken efforts to eliminate variation
within the fixturing system.
Mr. Arbic emphasizes that there’s nothing
lacking about off-the-shelf tooling from System
3R. Rather, the chief concern was the interface
between the supplier’s precision-engineered
components and the workpiece itself, which varies
by user and can’t always be guaranteed by the
supplier. At Omega, this interface takes the form
of custom, high-precision subpallets in various
sizes and configurations, all designed and machined

The Grob G350’s horizon-

tal, retractable spindle
and single-sided, 180-
degree trunnion ensure
a spacious workzone.
Its 202-position tool-
changer is loaded with
a standardized selection
of cutters, all of which
are guaranteed within
10 microns, mounted in
shrink-fit holders and
tied to material-specific
parameter settings within
the shop’s CAM software
tool library. Specifiying
the table without T slots
evidences Omega’s com-
mitment to eliminating
process variation.

mmsonline.com January 2017 MMS 73

FEATURE
Omega has two Grob G350
five-axis machining centers. The
second was outfitted for automa-
tion, but this one, the shop’s
first, isn’t tended by the robot.
Still, System 3R fixturing keeps
the machine integrated with
Omega’s standardized
manufacturing system.
in-house to ensure the fit with the work is just as
exacting as the fit with the chuck on the machine
table. The shop has also taken steps to keep parts
secure when exposed to milling forces that typi-
cally exceed anything they would experience
74 MMS January 2017 mmsonline.com
during sinker EDM burning. “Making our own
subpallets allows us to take advantage of System
3R’s accuracy, but double and triple the size of
the component we can mount,” he explains.
All pallets are surface-ground to ensure size
varies by no more than 0.0001 inch. Attention
was also given to the shape and the pattern of
the set of holes linking subpallet to work as well
as those linking custom subpallet to System 3R
pallet. Experimenting with these and other features
has enabled the shop to develop a system that
ensures exacting precision and rigidity all the way
from chuck to workpiece, Mr. Arbic says. Raw
stock is cut from square barstock into blocks
measuring 2.5 by 2.5 by 3.5 inches (large enough
to cover most work), and pre-machined, pallet-
connecting hole patterns provide a mix of hori-
zontal and vertical mounting configurations. Setup
personnel simply select the proper block, mount
it to a pallet, insert the pallet into the robot car-
ousel, and let the part program do the rest.
The shop’s common master reference, a cus-
tom-designed tooling ball, is just as important as
precise fixturing for ensuring parts can removed
and placed back into the system without re-
alignment, Mr. Arbic says. For every job, this
tooling ball is referenced in the CAD file along with
a model of the pallet. By locating every feature of
This air-amplification system on the back of the
G350 machine ensures the System 3R chuck securely
clamps even the largest parts. Air supply is controlled
by the robot, and various safety mechanisms ensure
the chuck stays clamped in the event of a power
outage or other unexpected loss of air pressure.

every part in relation to the ball geometry, pro-
grammers ensure consistent quality across all
work. When a pallet moves to a new machine, the
only extra step is a brief spindle probe touch-off
to confirm not part zero, but the machine’s own
zero position. “What (Mr. Arbic and the rest of the
team) have done is packaged a method of refer-
encing all workpieces through the entire process,
and that scheme is a standard for Omega,” Mr.
Heckendorn says.
Getting here wasn’t “rocket science,” Mr. Arbic
says about the shop’s work with its pallets and
referencing scheme. In fact, he claims any shop
with sufficient expertise could likely do the same
thing with a system as exacting as System 3R’s.
That’s not to suggest such expertise is easy to
find, or that applying even basic physics and
engineering principles is easy. “It took a lot of trial
and error, and having a collaborative internal team
of lead moldmakers, tooling engineers, experi-
enced CNC programmers, operators and design-
ers made all the difference,” he says.
The System 3R-based tooling extends stan-
dardization and control beyond machines directly
tended by the robot. For example, manually load-
ing the shop-floor CMM (coordinate measuring
machine) is fast and easy enough that every part,
including all electrodes, can be inspected without
affecting the shop’s average three- to four-week
lead times. Fast, repeatable setups also make it
viable to remove parts from the pallets on manu-
ally loaded wire EDM machines rather than the
cruder sawing process. In addition to being
more precise, the EDM can eliminate an extra
setup when geometry must be wire-cut into the
FEATURE
Precisely repeatable
fixturing enables seam-
lessly incorporating
machines not tended by
the robot into the
process flow, including
wire EDM units and,
as shown here, the
toolroom CMM.
mounting face of a part anyway. Even the Grob
must be loaded manually with the largest mold
bases and base plates because the robot’s weight
limit is 110 pounds. Nonetheless, a common
workholding interface keeps it integrated with the
shop’s manufacturing system.
At first, leadership had to enforce adherence
to the palletization system, he adds. However, it
didn’t take long for crewmembers to begin request-
ing pallets on their own for virtually everything,
including very basic components like custom
fixtures, gibs, stripper plates and other minor
assembly items. The system’s stability and preci-
sion also facilitates mounting long or odd-shaped
components that wouldn’t have previously seemed
suitable for pallets, such as custom ejector pins.
“Pretty much everything here goes on a pallet,”
he says.
SCALING UP
The first custom subpallets were developed for
the smallest work: 5-by-8-inch core and cavity
inserts for the quick-change mold frames favored
by company’s bridge tooling customers. Once
finalized, the subpallet design was simply scaled
up to also cover 7-by-11-, 10-by-15-, and, finally,
18-by-18-inch plates. Today, Omega employs a
combination of small, medium and large custom
subpallets of various styles as well as multiple
variations of System 3R pallets in 54-mm, 70-mm,
and 156-mm sizes.
Machining scaled up along with workholding,
both in terms of size and sophistication, Mr. Arbic
says. The first major change was from a three-axis
VMC to one with a two-axis rotary table that
mmsonline.com January 2017 MMS 75
FEATURE
enabled 3+2 machining. This eliminated the need
for manual setup adjustments to provide spindle
access to multiple part faces. However, he says
that machine’s rotary table, spindle housing and
other components left no room for larger parts
like mold bases and base plates, particularly when
mounted on pallet stacks. The model in place
now, Grob’s G350, suffers no such restrictions,
offering the ability to accommodate blocks even
larger than the 18-by-18-by-3-inch plates for the
largest, standard quick-change frames. With an
auto-opening door, a feature requested by Omega
and incorporated by Grob, the machine can also
be integrated with the robot. That’s a contrast
with previous models that required human oper-
ators to swap pallets in and out of the table chuck.
The machine’s spacious workzone is thanks
largely to its horizontal spindle, which retracts
back into the enclosure (including for toolchanges),
as well as its one-sided trunnion table, which can
flip a full 180 degrees. These two features allow
the shop to machine mold base waterlines as
deep as 22 inches by drilling to half depth, then
flipping the part to bore the rest of the hole from
the other side, Mr. Arbic says. Along with carefully
pro gra m m e d 3+2 m ac hining rou tin e s, this
configuration also makes complex features
more accessible than ever before, he adds. That
Omega Plastics Inc., call 586-954-2100
or visit opinc.com.
GF Machining Solutions (System 3R),
call 847-439-4888 or visit system3r.com.
Grob Systems Inc., visit grobgroup.com.
76 MMS January 2017 mmsonline.com
Stored by material type
in horizontal and vertical
configurations, standard-
size blocks of raw stock
with connecting hole pat-
terns already machined
ensure easy, fast pallet
mounting at the outset of
any job.
facilitates the use of shor ter, more rigid tool
assemblies to achieve tighter tolerances and
smoother finishes. The machines’ 202-tool-
capacity automatic toolchanger (ATC) also prevents
tool availability or breakage from limiting lights-out
capacity. He adds that the combination of a
26,000-rpm, HSK63A spindle and 63 Nm of torque
provide versatility for both heavy material removal
and fine finishing operations.
Grob and Grob dealer Merrifield Machinery
Solutions (Pontiac, Michigan) deserve much of
the credit for getting the machine up and running
in the way the shop prefers, Mr. Arbic says. For
instance, few users request smooth worktables
with nothing but a specific chuck style (a choice
that provides a mild chip evacuation advantage
while also evidencing the shop’s confidence in
its manufacturing strategy). Another example
was the addition of a pneumatic amplification
system at the back of the machine, a project that
also involved consultations with System 3R
re pre se ntative s. Picture d on page 74, this
system boosts the locking force of the System
3R MacroMagnum automatic table chuck to its
maximum. That wouldn’t have been possible
with standard shop air.
Altogether, the new machine and modified
fixturing have advanced the cell to the point where
it can accommodate about 80 percent of all
Omega’s work. Based on this shop’s experience,
near-comprehensive automation in a high-mix,
low-volume environment like a mold shop is
anything but out of reach for anyone with not only
the expertise, but the will to make it happen.
 The master of speed
� KR AGILUS series

When it comes to handling tasks,

the KR AGILUS offers impressive
results combined with minimized
cycle times. At the same time, the
speed and accuracy make the
performance of this small robot
family unique in its payload
category. Available in 6 and 10 kg
pa
payloads with an available reach of
700, 900, and 1,100 mm.

kukainfo@kukarobotics.com
1-800-459-6991
FEATURE

78 MMS January 2017 mmsonline.com


Turn-Mill Technology
Improves Industrial
Motor Performance
By replacing a welding process to create rotor cooling channels with multi-
tasking machining from a solid forging, Siemens Norwood in Ohio has realized
improved induction motor vibration qualities and much faster overall rotor
production times.
BY DEREK KORN
I n some cases, an improvement to a machining
process or the addition of a new machining
capabilit y leads to improvements in an end
product’s performance. The latter has been the
experience at the Siemens Large Drives motor
plant in the production of its A bove NEM A
horizontal AC induction motors that range to
18,000 horsepower.
This successful line of motors is produced at
the company’s 119-year-old Norwood manufac-
turing facility in Cincinnati, Ohio. The motors are
used in various industries such as mining, chem-
ical, power generation, pulp and paper, and oil
and gas. One key motor component is the rotor
shaft that installs a stator. Antonio Lassandro,
Siemens Norwood’s senior manufacturing engi-
neer, says rotors for these motors range from 5
to 13 feet long and have diameters from 8.5 to 20
inches. Made from steel forgings, these rotors
(which the team there has nicknamed “logs”) can
Turn-mill technology enables the Siemens Norwood
facility in Cincinnati, Ohio, to more effectively manu-
facture rotors like this for its large Above NEMA AC
induction motors.
FEATURE
weigh as much as 6,000 pounds.
A number of machining operations are required
to produce a finished rotor from a shaft forging,
including rough and finish turning; milling, drilling
and tapping; as well as cylindrical grinding and
hand diamond burnishing of key surfaces. Stress
relieving of rotor shafts and final rotor-assembly-
balancing operations are also performed.
Although all of these operations are still required
today, it’s now possible for Siemens Norwood to
complete all the machining work on one multitask-
ing machine in only two setups, rather than send-
ing workpieces across various pieces of equipment,
such as lathes and horizontal mills, as it once did.
Just as importantly, a manual welding process
was eliminated that not only greatly reduced rotor
manufacturing time, but improved the vibration
characteristics of the company’s motors.
“FLUTING,” NOT WELDING
In order to cool a stator during motor operation,
the section of the rotor inside the stator includes
a number of straight, longitudinal channels that
serve to direct air through and out of the stator.
Initially, Siemens Nor wood welded multiple
mmsonline.com January 2017 MMS 79
FEATURE
The Above NEMA motors are used for oil and gas and
a range of other industry applications. Motors are
available in models ranging to 18,000 horsepower.
rectangular blanks about the periphery of a cylin-
drical rotor forging to create those cooling chan-
nels (see the photo below). Prior to welding, the
rotors were rough-turned on a lathe and then sent
to a four-axis horizontal mill that machined flats
where the blanks would be located for welding.
The manual welding process for each rotor
took 50 to 60 hours, and this approach meant
other subsequent manufacturing steps also
became necessar y. For example, the welds
required quality inspections to ensure that proper
penetration was achieved and that the welds were
free from cracks. In addition, a pre-balancing
operation for just the shaft was commonly per-
formed prior to balancing the entire rotor assem-
bly. This was necessary because of the natural
imbalance that occured due to the inherent vari-
ation in resulting weld thickness from one welder
to another.
Plus, the heavy welding operations created a
80 MMS January 2017 mmsonline.com
good bit of stress inside the rotor. Kris Miller,
systems engineering manager, explains that, as
a motor heats up during operation, the stresses
in rotors with the welded-shaft design change
and shift, causing an imbalance that’s evident in
vibration testing.
These issues spurred the decision to adopt a
multitask machining process using a large turn-
mill machine with a B-axis milling spindle that
could mill away the cooling channels from larger-
diameter forgings in a process the company now
calls “fluting.” This technique completes cooling
channels on large shafts in what the company
describes as substantially less time than the
welded design. In addition, the consistency of
machining to create channels compared to manual
welding has eliminated the need to perform rotor
pre-balancing. Good initial rotor balancing char-
acteristics also help eliminate lobing that might
otherwise occur during subsequent cylindrical
grinding operations, which could extend overall
rotor assembly balancing time.
After considering a few turn-mill brands, the
company chose an M-80 Millturn from WFL, which
is headquartered in Linz, Austria. (WFL’s U.S.
headquarters is located in Wixom, Michigan, and
Siemens Nor wood purchased this par ticular
machine through WFL distributor Walker Machin-
ery in Cincinnati, Ohio. This machine was installed
in the fall of 2015.)
There are a number of requisite machine
Previously, the company created cooling channels by
manually welding rectangular blanks to shafts. Not
only was this time consuming, but the heavy welds
also introduced stresses that required additional rotor
balancing work prior to motor assembly.

features needed to effectively process these
rotors, and size is one. The M-80 with tailstock
can swing 39-inch-diameter workpieces with the
steady rests removed and accommodate material
as long as 236 inches between centers. It also
features a 100-horsepower main spindle and an
80-horsepower B-axis milling spindle offering
220 degrees (±110 degrees) rotation. Mr. Lassan-
dro says every one of the automatic toolchanger’s
72 stations is used for a range of tools that have
a Capto C8 tool interface. The M-80’s slant-bed
design is important, too, to provide easy operator
access to the work area during setups.
Due to the length of these rotors, program-
mable steady rests from SMW Autoblok are used
to provide additional support. Three steady rests
were purchased with the machine (two large and
one smaller), although only two are installed on
it at any given time. During fluting, the steady rests
clamp on diameters on either end of the shaft to
provide additional rigidity, minimize vibration
during machining and prevent workpiece sag.
Mr. Lassandro says the complexity of the
machine presented him with a programming
FEATURE
This M-80 Millturn from WFL is the multitasking
machine Siemens Norwood chose to perform “fluting”
operations to create the rotor cooling channels from
a solid, cylindrical steel forging. The turn-mill machine
features a 100-horsepower main spindle and
80-horsepower B-axis milling spindle. It can
accommodate 20-inch-diameter shafts as long as
236 inches, which Siemens Norwood will take
advantage of as it continues to design larger motors.
learning curve. This he overcame in part through
training at WFL’s Linz headquarters. It was also
helpful that WFL developed a part program for
one rotor model that was machined during runoff
test cuts performed in Linz to prove the process.
Mr. Lassandro then worked closely with Siemens
Norwood’s engineering department so it under-
stood the machine’s capabilities and with the
machine operators so they had a good feel for
the new process, machining codes and cycles.
That said, although the rotor models are
similar, each often has slight design differences.
Plus, rotors are machined in batches of one or
two, not hundreds, meaning new programs
are developed quite frequently. Therefore, Mr.
L assandro has star ted to build a librar y of
programs for common rotor styles that he can
call up, swap the 3D model for the new job, and
then tweak to adjust for different flute depths,
bearing diameters, keyway specifications and
Offline simulation is performed for each job to ensure
there will be no interferences or collisions during the
actual operations. A feature in the Crash Guard Studio
software enables Mr. Lassandro to quickly remove
workholding elements to get a clearer view of the
cutting tool motion.
mmsonline.com January 2017 MMS 81
FEATURE

A face mill is used to create cooling channels when

there are only a few flutes, such as the six-flute
version above. Conversely, slot cutters are used when
there are a larger number of flutes and minimal space
between them.

so on, before regenerating a new program.

The type of tool used for fluting depends on
how many channels a particular rotor has. For
large shafts that have perhaps six flutes, a Sand-
vik high-feed face mill is used to create the cool-
ing channels, because there is ample space
between flutes. For rotors that have many more
flutes, a Sandvik 10-inch slot cutter is used (see
photo above).
The M-80’s capabilities have spurred the facil-
ity to use carbide tooling instead of high speed
steel as it had traditionally used, too. Mr. Lassan-
dro says the facility takes advantage of the M-80’s
1,160-psi through-tool coolant delivery to provide
effective chip evacuation while using solid carbide
drills. In some cases, it would take several minutes
to drill a 4-inch-deep hole on a horizontal mill by
pecking with a high speed steel drill. That same
hole now takes only 15 seconds to create without
WFL, call 248-347-9390 or visit wfl.at.
Walker Machinery, call 513-271-3380
or visit walkermachinery.net.
Siemens Norwood, call 513-841-3100
or visit siemens.com.
Sandvik, call 800-726-3845
or visit sandvik.coromant.com.
pecking using a solid carbide drill and high-
pressure through-tool coolant delivery.
In-process part probing also plays a role. Tools
can be automatically measured using a WFL tool-
setting probe, eliminating the need to perform
offline tool measurement or manual touch-offs.
An M&H touch-trigger probe is also used primar-
ily to set all machine offsets. For example, after
fluting work is completed on a rotor, the rotor’s
C-axis zero position is determined by probing
either side of one flute to ensure that the keyway
machined at that location is positioned precisely
at the center of that flute.
Each part program that is developed is verified
through offline Crash Guard Studio simulation
software. This software uses CAD models of all
machine elements, workholding devices, tooling
and so on to ensure there will be no interferences
or collisions during the actual operations on the
machine. The software includes a helpful feature
that enables Mr. Lassandro to quickly remove
workholding elements such as the tailstock to get

82 MMS January 2017 mmsonline.com


a clearer view of the simulated cutting tool motion
down the length of a part. The machine operators
can also access Crash Guard from the machine’s
Siemens 840D control, which shows the motion
of machine elements in real time, and prevents
accidents from occurring on a new program’s
first run and initial setup of clamping devices.
WHEN NOT TO MULTITASK
Like most other companies that purchase a turn-
mill such as the M-80, Siemens Norwood is able
to machine many workpiece features in one
clamping. That said, there is often so much flut-
ing work to be done on that machine that the
company will use one of its traditional CNC lathes
to perform initial rough-turning operations for
shafts, rather than tying up the M-80 for that
basic work. After rough turning, those shafts are
sent back to the turn-mill for fluting. Finish turn-
ing might also be completed on the M-80, unless
it makes more sense to send the rotor to another
lathe for finish turning to enable the turn-mill to
start another fluting job.
On the other hand, when there’s not so much
fluting work scheduled, the shop might run
FEATURE
Tools can be changed out of the ATC magazine with-
out shutting down the machine while it is operating.
Solid carbide drills combined with high-pressure cool-
ant enables deep holes to be drilled without pecking.
simpler shaft work that doesn’t require fluting
across the M-80 in order to get most if not all
turning and milling work completed in one setup.
That eliminates work in process ( WIP) when
shafts require milling but the horizontal mill is
tied up with other work.
Bruce Tillinghast, Walker Machinery president,
says Siemens Norwood actually considered adding
this type of multitasking equipment platform some
20 years ago, but decided against it. At that time,
all the necessary elements—software, hardware,
tooling, training and so on—simply didn’t jell into
the type of repeatable process that’s currently
possible with today’s turn-mill and related machin-
ing technologies. The system also wouldn’t have
been as reliable, he says, which is important given
not only the significant investment Siemens Nor-
wood made in its turn-mill machine, but also
because it is the only machine in its plant that can
perform fluting work.
The machine features touch-trigger probing, which
is primarily used to speed setups. For example,
probing either side of a flute enables the rotor to be
positioned properly in the C axis for milling a critical
keyway. Plus, it is possible to park a fully opened
large steady rest near the chuck as it is shown here
rather than removing it from the machine to enable
the milling spindle to access features on short shafts.
Otherwise, removing and replacing a steady rest
takes time, because it must be properly aligned with
the chuck center line.
mmsonline.com January 2017 MMS 83
FEATURE

84 MMS January 2017 mmsonline.com

 FEATURE

JIMTOF:
A Strong Embrace of IIoT
The recent Japan International Machine Tool Fair reflects the rapid move
toward smart factories in which smart machines are fully networked.
BY MARK ALBERT

T he message from JIMTOF 2016, Japan’s

premier machine tool show, was strikingly
clear: Japanese providers of manufacturing
technology have embraced the concepts of the
Industrial Internet of Things (IIoT). Although there
is no exact definition for what this phrase means,
it undoubtedly refers to the strategy of linking
machine tools and other shopfloor equipment to
a web-enabled network that makes manufactur-
ing increasingly data-driven. (The trend to data-
driven manufacturing is more commonly referred
to as Industry 4.0 among European developers,
but this term was quite rarely used at JIMTOF.)
When machines are connected to a network,
a stream of data reflecting their operational status Mazak’s booth was literally centered around this
and the condition of their components and sub- portrayal of IIoT solutions. All of the machines in the
systems can flow to processing centers on vari- surrounding booth space were actively monitored.
ous levels for monitoring, analysis, decision- Displays included data from machines being monitored
making and problem-solving. In fact, the Japanese in the company’s factories in Japan.
Machine Tool Builders’ Association (JMTBA), the
organization sponsoring JIMTOF, identified IIoT able information to avoid downtime and improve
as the main component of its stated JIMTOF productivity through more thorough and
theme of “The Future Starts Here.” timely monitoring.
T he IIoT capabilities of various machine The show also indicated that, for machine tool
builders in Japan were prominently displayed in builders, the premier interoperability/data exchange-
booth exhibits. In general, these exhibits high- ability standard is MTConnect, which is apparently
lighted how data can be transformed into action- being widely adopted to promote shopfloor con-
nectivity. MTConnect is described as a set of
Visitors to JIMTOF 2016 “saw” a lot of interesting open, royalty-free standards intended to foster
new machine tool technology. This massive sculpture greater interoperability between machines, devices,
is part of the striking garden decor near the main control systems and software applications. Orig-
entrance to Tokyo Big Sight, home to JIMTOF. inally developed in the United States through the

mmsonline.com January 2017 MMS 85

FEATURE
support of AMT—The Association For Manufactur-
ing Technology, Japanese builders took an
early interest in MTConnect. Most notably,
Mazak Corp.’s North American manufacturing
headquar ters in Florence, Kentuck y, made
MTConnect a major part of its iSmart Factory
concept. MTConnect is now reportedly utilized in
several Mazak plants in Japan as part of the
company’s thrust toward IIoT technology.
Significantly, a seminar on MTConnect was
also presented at JIMTOF under the sponsorship
of AMT. Attendance at this seminar indicated
strong interest in the standard by both technology
developers and end users.
TWO BIG CHALLENGES
In addition to interoperability and data exchange-
86 MMS January 2017 mmsonline.com
Incorporating a configurable network switch is an
effective, manageable approach to keeping con-
nected machine tools safe from security threats on
a network. Okuma’s Netbox Suite, which includes
a network switch, becomes part of the machine’s
electronic control system. One use for it is to give a
legacy machine secure connectivity.
ability, JIMTOF exhibitors are confronting two
other major challenges in IIoT implementation:
network security and effective data computing.
For network security, two approaches, both
involving network switching and routing, were
apparent. One is to embed a configurable network
switch inside a machine’s CNC to manage network
exposure internally. The other approach is to “bolt
on” an external device that incorporates the net-
work switch and forms the secure interface to the
network. Builders promoting IIoT-ready systems
seem to be favoring the former approach, whereas
builders striving for IIoT compatibility of existing
products and legacy machines in the field are
favoring the latter. These approaches are not in
conflict, but rather represent the range of options
available for IIoT implementation.
The challenge of effective data computing boils
down to a very practical matter. Because the flow
of data from connected machines can be volu-
minous, managing when, where and how to
process this data is critical. Although cloud-based
applications can bring to bear virtually unlimited
computing power to the tasks of collecting, ana-
lyzing and storing vast amounts of data, deriving
and delivering actionable intelligence to the shop
floor in a timely fashion is a problem. It is eliciting
an alternative concept—that of “edge” computing
or computing in the “fog.” At JIMTOF, this devel-
opment was most plainly proposed by FANUC,
Japan’s largest CNC and factory automation
supplier. It is embodied in the company’s FIELD
(FANUC Intelligent Edge Link and Drive) system,
an emerging automation platform being developed
with partners such as Cisco, Rockwell Automation
The FANUC booth had this IIoT display showing the
status of almost all of the machine tools running
at JIMTOF. Network hardware and software for the
FANUC Intelligent Edge Link and Drive (FIELD) System
were also featured.

and Preferred Networks.
Here, the principle is to conduct data comput-
ing and analysis with resources shared within a
corporate network, but away from a centralized
capability such as a cluster of servers in one
location. In this usage, “edge” has two connota-
tions: computing stays within the boundaries
of the network, but away from the center. Like-
wise, “fog” computing implies that resources
such as CPUs and memory banks in the network
can be shared when tasks are distributed among
them. If fog is literally a cloud on the ground,
then figuratively, fog computing is cloud-like yet
stays grounded in the local plant network.
The FIELD system is currently proving its value
in “deep learning” applications that enable vision-
equipped robots to enhance bin-picking capabil-
ity. Analysis of each robot’s successful and
unsuccessful attempts to locate and grasp a
randomly sorted part yields new and better rules
to guide the robots, making all of them more
effective (“smarter”) as a group.
OTHER NOTEWORTHY TRENDS
Making machine tools ready for IIoT was certainly
not the only significant trend detectable at JIMTOF.
Hybrid machines that combine subtractive pro-
cesses (conventional milling, grinding, turning
and so on) with additive processes (laser cladding,
wire arc welding, laser metal deposition) were
notable. The Japanese government is providing
substantial funding for research in hybrid technol-
ogy, and this showing reflects that support.
Additionally, several builders have incorporated
collision-avoidance features into the software in
the CNC. Essentially, the simulation of the machin-
ing program stays ahead of its actual execution,
creating an opportunity for the software to detect
and avoid impending crashes or interference.
Similar protection safeguards axis moves when
the operator is jogging the machine into position.
Another frontier that machine tool builders are
pushing into is machining accuracy in the sub-
micron level. Applications range from miniaturized
electronics to advanced designs of airspace
components such as jet engine blades.
Finally, it should be noted that JIMTOF 2016
marked the opening of two new exhibit halls,
thereby increasing exhibit space to nearly 100,000
FEATURE
square meters. The new halls, East 7 and 8, were
dedicated largely to overseas exhibitors who have
been closed out of this show in the past because
of strong participation by domestic exhibitors.
Adding a new show entrance by the new halls
helped improve visitor traffic to the exhibit space,
although some long-time exhibitors who were
seemingly relegated to the overseas exhibit area
this year were not entirely pleased.
Overall, JIMTOF is at once a manageable show
size-wise, yet gratifyingly innovation-rich. And
characteristically, the Japanese combine orderli-
ness with flair, daring technology with graspable
objectives, and bold moves with respect for tradi-
tion. JIMTOF exemplifies monozukuri, a Japanese
word that means “the art of making things better
than ever.” It can also be translated as “the proud
Japan’s focus on hybrid (additive and subtractive)
machining platforms is part of its Technology Research
Association of Future Additive Manufacturing (TRAFAM)
program. This government/industry initiative is
intended to put Japan in the forefront of additive
manufacturing developments.
spirit of dedicated craftsmanship.” Monozukuri
gives JIMTOF a zest that distinguishes it from any
other show.
LEARN MORE
To see a slideshow that samples other
exhibits at JIMTOF, go to short.mmsonline.
com/jimtof16.
mmsonline.com
mmsonline.com January 2017 MMS 87
BENCHMARKING YOUR MACHINING BUSINESS

Mallory Industries, Inc.

33 Spring Lane
Farmington, CT 06032
Phone: 860-677-2895
Fax: 860-677-8815
malcams.com

COMPANY DESCRIPTION
WEBSITE
Mallory Industries is the 2016 Top Shops Honors
malcams.com Program winner in the survey’s human resources
category. Noteworthy are the shop’s very low
employee turnover rate and generous benefits
package, including a matching 401k plan, bonus
programs, employee stock ownership plan
(employees own more than 30 percent of the
company) and health insurance offering.

Led by Paul Murphy, president, Mallory Indus-

tries’ niche is manufacturing 2D and 3D cams,
although it also produces various other complex
machined components and assemblies. The
shop was founded in 1956 and currently has
41 employees and a 22,000-square-foot facility.
In 2015, Mallory Industries was recognized
END MARKETS SERVED nationally as one of 11 “Young Adult Employer
Champions.” This award honors employers
• Aerospace
who have made a lasting investment in young
• Commercial
adult workers.
• Energy
• General industrial

WORKPIECE MATERIALS
COMMONLY MACHINED
• Aluminum
• High-temperature alloys
• Low-alloy steels
• Stainless steels
• Tool steels
• Toughmet

88 MMS January 2017 mmsonline.com

 BENCHMARKING YOUR MACHINING BUSINESS

Mallory Industries is committed to a culture that is

rooted in lean manufacturing initiatives. Employees
are constantly trained in setup reduction, mistake
proofing, standardized work and root-cause analysis.
Other lean concepts include 6S workplace organiza-
tion, visual boards, kitting for all machining jobs,
total preventive maintenance, and daily Gemba
meetings and shopfloor walks.

The apprenticeship program in

place at Mallory Industries is
beneficial in a number of ways.
For example, apprentices produce
while learning; there’s reduced
turnover because apprentices
know they have jobs with a future;
it serves as a dependable source
of trained workers; and it leads to
improved labor relations because
the program is a cooperative
effort between employee
and employer.

Mallory Industries has a range of machining

capabilities. Resources include 34 cam
milling machines, five turning centers, two six-axis
turn-mills, seven three- and four-axis VMCs and
one HMC as well as EDM, grinding and honing
equipment. The shop also has two CMMs, a laser
marking machine, a tool presetter and manual
machines. Still, its focus on workforce develop-
ment has also been a key to its success. This
is exemplified by its winning the “Young Adult
Employer Champions” award through its promotion
of effective hiring techniques and access to onsite
training and skills-development opportunities.

mmsonline.com MMS January 2017 89

BETTER PRODUCTION Shops Using Technology

Precision Profiler Opens

Opportunity for
Larger Aerospace Parts
FORT WALTON MACHINING
PROBLEM Could only process smaller aero-
space parts without investing in large,
expensive-to-operate equipment
SOLUTION Vortex horizontal profiler 160
from Mazak
RESULTS Increased part size capabilities,
improved cut tolerance and finish
I n today’s aerospace market, shops typically
have two options: Cut aircraft structural com-
ponents shorter than 11 feet long using five-axis
Fort Walton Machining’s VHP 160 features two-
table changing capability for continuous, uninter-
rupted operations. If needed, the shop can expand
its single-machine, two-table configuration into a
manufacturing cell with the addition of both tables
and machines.

EDITOR EMILY PROBST, eprobst@mmsonline.com

90 MMS January 2017 mmsonline.com

 © 2016 SCHUNK INTEC, Inc
www.us.schunk.com/chuckjaws

1,200 Standard
Jaw Types from
a single Source High tech from a family-owned company

The world’s largest selection, for every 100% individual

conceivable use, of power chucks and Customized chuck jaws
toolholders from a single source internal clamping, axially alternating.

Jens Lehmann, German goalkeeper legend,

SCHUNK brand ambassador since 2012
for precise gripping and safe holding. SCHUNK claw jaws Quick-change Stepped jaws
www.us.schunk.com/Lehmann jaw system
BETTER PRODUCTION Shops Using Technology

The VHP 160 from Mazak Corp. enhanced the shop’s

cutting capabilities, helping it find its niche in terms
of part processing. The machine’s work envelope
can accommodate about 70 percent of all the
common large-size airframe and aerospace parts.

machining centers or purchase expensive-to-

operate gantry-type equipment to reach beyond
that size limitation to 22-feet long, says Greg
Britton, CEO of Fort Walton Machining. Not sat-
isfied with either option, the company recently
acquired an advanced profiling machine system
from Mazak Corp. (Florence, Kentucky) that has
enabled it to increase its size capabilities while
remaining competitively priced.
The shop, located in For t Walton Beach,
Florida, is a high-mix/low-volume supplier with
lot sizes ranging from one to 500 parts. Eighty
percent of these parts are made from aluminum,
with tolerances ranging from 0.030 inch to as
tight as 0.00005 inch. It also machines carbon

MicroCentric Quick
Fast Changeover, High Accuracy,
Rapid Change™Jaw Chucks
New Rapid Change Power Chucks
feature a patented jaw dsign where
only the top jaw is changed, elimi-
nating the investment in multiple
sets of base jaws or expensive mono
block jaws.

Precision Workholding Technology

www.microcentric.com
 Shops Using Technology BETTER PRODUCTION

The machine’s
symmetrical base/
column construction
works in conjunction
with an advanced
coolant and chip
disposal system
to minimize heat
displacement.

Change Chucks
Increased Flexibility and Productivity
Quick Change Collet Chucks
MicroCentric introduced Quick Change
Collet Chucks to North America
in 1986. We offer Dead Length
and Pull Back designs for Bar
and Chucking applications up
to 160mm (6.3”) capacity.

FINISHES
FOR IRON, STEEL
& ALUMINUM
TRU TEMP® black oxide for iron and steel. 30 minute
process operates at 200oF and creates a black magnetite finish.
PRESTO BLACK® cold blackening for iron and steel. 20
minute process operates at room temperature and creates a
satin black finish.
MICROLOK® MZN zinc phosphate for iron and steel. 20 minute
process operates at 140oF and creates a matte grey finish.
LUMICLAD® black oxide for aluminum. 30 minute process
operates at 200oF and creates a satin black finish.
FREE SAMPLE FINISHING – Send parts & we
test and provide recommendations.
www.birchwoodtechnologies.com
TOLL FREE 1.800.328.6156
94 MMS January 2017 mmsonline.com
BETTER PRODUCTION
Shops Using Technology
ste els, aircraf t ste els, high-temperature
alloys and titanium. Its aircraft/aerospace work
encompasses cargo-handling systems, floor
supports and airframe components, as well as
brackets and other smaller parts. In addition to
aerospace work, Fort Walton Machining produces
medical equipment par ts and does general
machining work.
While jobs can be diverse, the common denom-
inator is the high level of required quality and
precision. The company must provide these,
along with fast deliver y, to stay ahead of the
competition. One way it does this is by investing
in advanced technology.
“If we aren’t on the cutting edge technology-
wise, our competition will run right over us.
Advanced technology is everything to our busi-
ness,” says Tim McDonald, production manager.
The lion’s share of the company’s machine
tool technology is from Mazak. Its more than 20
Mazak machines include various models of Quick
Turn Nexus multitasking machines, Variaxis five-
axis vertical machining centers, Slant Turn Nexus
turning centers and Vertical Center Nexus machin-
ing centers.
However, the machine that has enabled Fort
Walton Machining to find its niche within the
aerospace sector of its business is the Vortex
Horizontal Profiler (VHP) 160. Mazak designed
it specifically for the aerospace market with a
work envelope that can accommodate about 70
percent of common, large-size air frame and
aerospace parts. The number of shops that can
cost-effectively process such parts is limited,
the company says.
Travels measure 165.35 by 59.06 by 21.65
inches in the X, Y and Z axes, and a 106-horse-
power, 26,000-rpm, HSK-A63 integral-motor
spindle is standard. The large 157-by-49-inch
vertically integrated worktable enables the VHP
160 to easily accommodate a maximum load
capacity of 6,615 pounds.
For t Wa lton M ac hining c a n posi tion the
machine’s worktable horizontally for quick and
easy loading and setup, then return it to a verti-
cal position for machining operations. This ver-
tical orientation makes use of gravity and ensures
excellent chip evacuation during high-material-
removal operations, the company says.
 Shops Using Technology BETTER PRODUCTION

For t Walton Machining’s VHP 160 model
features two-table-changing capability for con-
tinuous, uninterrupted operations. If needed, the
shop can expand its single-machine, two-table
configuration into a manufacturing cell with the
addition of both tables and machines.
The profiler has a special box-type construc-
tion that integrates its base, column and table
to provide maximum machining rigidity for over-
all part accuracy. Furthermore, the machine’s
symmetrical base/column construction works
in conjunction with an advanced coolant
and chip disposal system to minimize heat
displacement.
For getting into the cut as quickly as possible
Mazak Corp., call 859-342-1700
or visit mazakusa.com.

INTRODUCING

Circle-Segment Machining
A Totally New Milling Strategy

Taper

Larger radii
removes more
material

Barrel Oval

cycle time
Lens
80% reduction!
Remove More Material in Software Partners:

Fewer Passes
With Emuge’s revolutionary NEW Circle-Segment end
mills design and leading edge software, 5-Axis milling of
molds, blades and other complex parts is incredibly faster,
removing more material in fewer passes with superior
surface finishes and minimal tool wear.

The Circle of Technology and Performance

Exclusive to Emuge. Learn more at www.emuge.com 800-323-3013 • www.emuge.com

mmsonline.com January 2017 MMS 95

 WHY WE DO IT

CLEAN AIR
MATTERS
We believe breathing clean air is a human right that employees,
friends and family members in the workplace all deserve.
Contact Camfil APC to learn more.

camfilapc.com/cleanairmatters

Handte Oil Expert

Oil Mist Collector
camfilapc.com/videos/expert

Handte EM Profi
Coolant Mist Collector
camfilapc.com/videos/profi

Dust, Mist and Fume Collectors

AIR POLLUTION CONTROL

www.camfilapc.com • e-mail: filterman@camfil.com • 844-638-9563

 BETTER PRODUCTION
Shops Using Technology

Search and shortening overall cycle times, the machine

system offers rapid traverse at speeds ranging

Machines to 1,380 ipm in the X axis, and 1,176 ipm in both

the Y and Z axes with an acceleration/decelera-

Smarter. tion rate of 0.5 G.

In addition to providing a niche in terms of
part-size processing, Fort Walton Machining
says the VHP 160 has enhanced its cutting
capabilities, particularly in aerospace compo-
nents that feature deep, thin-walled pockets and
require extensive metal removal.
“Anyone can machine a 0.050-inch-thick
wall that is only 0.100-inch deep/high,” Mr.
McDonald says. “But tr y holding tolerance,
straightness and required surface finish when
that thin wall is 3 inches high/deep. It all comes
Machine Type: down to your machine’s capabilities—speed,
accuracy and rigidity. Without the right machine
Machining Center
and tooling running at the right speeds and feeds,
Drill/Tap
you will never succeed.”
Boring Mill T h e p r of i l e r ’s s p e e d a n d a c c u r a c y a r e
Milling Machine also critical for achieving superior part finishes,
he says. A part’s aesthetics are important to
today’s aerospace companies. “While a part
may be machined to exact tolerances, sloppy,
a e s th e ti c a l l y d i s p l e a s i n g s u r f a c e f i n i s h e s
give the impression of imprecision, poor perfor-
mance and potential par t failure,” he says.
“Plus, the simple fact is that aircraft components
a r e e x p e n s i v e, e s p e c i a l l y t h e l a r g e r- s i z e
ones, and OEMs want perfection in both func-
tionality and aesthetics. With the VHP 160, we
can fulfill both requirements and reduce cost
p e r pa r t through optimize d setups, s p e e d
and precision.”
While Fort Walton Machining is planning to
bring in new work for the profiler, it has initially
moved some existing work over to the machine
to increase efficiency and reduce cost per part.
The Machine Tool Search Engine One such job is a radar shroud that is reduced
from 200 pounds of raw stock to only 35 pounds
after machining.
IN PARTNERSHIP WITH: “With the VHP 160, we improved part accuracy
and achieved seriously shor ter run times for
the shroud,” says Chad Wisenburger, CNC
techspex.com mill super visor. “The machine reduced cycle
time by 50 percent, and for us, that kind of
speed means less time spent, more parts and
more profit.”

mmsonline.com January 2017 MMS 97

BETTER PRODUCTION Shops Using Technology

Shop Vac Reduces

Unscheduled Downtime,
Safety Concerns
W hen Cianbro wanted to eliminate a hazard-
ous process in which workers manually
removed steel shot from an auger system con-
nected to a cabinet-style blast machine at its
40,000-square-foot fabrication and coating
facility in Georgetown, Massachusetts, the com-
pany decided to purchase a heavy-duty vacuum
from Vac-U-Max (Belleville, New Jersey). Beyond
eliminating the ergonomic hazards and potential
costs of injury, the company says the vacuum
has provided increased uptime, reduced man-
power, increased productivity, improved product
quality, and a healthier, cleaner environment.
Cianbro operates in more than 40 states
across a diverse range of markets, performing
c i v i l a n d str u c tu ra l p ro j e c ts f ro m b u i l d i n g
bridges to operating fabrication and coating
facilities, and working in power plants and
paper mills. The Georgetown facility fabricates
structural steel beams for bridge and building
projects. Many of these projects begin with
moving the beams via a conveyor system through
a c a binet-st y le bla st mac hine w he re ste e l
beads called “shot” remove rust and mill scale
in preparation for welding or painting. Once the
steel shot hits the beam, it drops down into an
au g e r syste m th at re c l a ims a nd fe e d s th e

CIANBRO
PROBLEM Needed to eliminate manual
handling of heavy material
SOLUTION 15-hp Vac-U-Max 1020MFG Designed for high-volume recovery in an
RESULTS Increased safety, reduced industrial setting, the 15-hp Vac-U-Max 1020MFG
downtime and wasted manpower continuous-duty vacuum is the ideal solution to
clean up heavy blast media.

98 MMS January 2017 mmsonline.com

BETTER PRODUCTION Shops Using Technology

material back into the blast machine for reuse. alleviate the ergonomic issues associated with
The sandblasting process is taxing on machin- manually shoveling heavy media in a tight space
ery, and when inherent breakdowns occur, work- and moving heavy drums. Kris Chipman, safety,
ers must remove all blast media from the system health and environmental super visor, began
to perform maintenance. Previously on those researching solutions, including some big shop-
occasions, workers used to sweep and shovel type vacuums.
the steel shot into drums and manually move After speaking with a Vac-U-Max representa-
them from the production floor using a dolly. tive, it quickly became clear that commercial,
Focused on safety, the company wanted to shop-type vacuums were insufficient to handle
the volume of heav y-
blast media, Mr. Chip-
man says. Instead, the
vacuum needed to be
designed for high-
volume recovery in an
industrial setting. The
solution for Cianbro was
Va c - U - M a x ’s 15 - h p
1020MFS continuous-
duty vacuum.
Even though the unit
is capable of recovering
as much as 5 tons per
hour and is designed to
pick up heavy materials
including steel shot,
foundr y s a nd, metal
powders, sludges and
other materials similar
in nature, Mr. Chipman
wanted final assurance
that the vacuum could
pick up Cianbro’s par-
ticular blast media.
“This is heavy stuff,”
he says. “Each 55-gallon
drum weighs approxi-
mately 2,000 pounds,
and from the beginning,
we were not sure if what
we wanted to do was
even possible. So we
s e nt Va c - U - M a x a
sample of the shot
media, they did some
testing and guaranteed
it would work for us.”
Although the 1020
unit is por table with

100 MMS January 2017 mmsonline.com

PRECISE, QUICK = EFFICIENT!
COST-CUTTING SOLUTIONS WITH SCHWANOG INSERTABLE TOOLING SYSTEMS

Available SCHWANOG
Tooling Systems:

// OD Grooving
// OD Grooving on rotary
transfer machines
// ID Grooving
// ID Turning
// Form Drilling
// Shave tools
// Skiving
vma-werbeagentur.de

// Polygon Turning
// Broaching of Serration
// OD Whirling
// ID Whirling
// Selector system
www.schwanog.com

Schwanog LLC
Elgin | Illinois
Toll free: 888-870-1055
info.usa@schwanog.com
BETTER PRODUCTION Shops Using Technology

Vac-U-Max heavy-duty industrial vacuums reduce

the risk of injuries, enabling Cianbro to quickly and
safely clean track augers.

14-inch rubber tires and a dual swivel caster

w h e e l t h a t m a ke s i t e a s i l y m a n e u ve r a b l e
by a single operator, Cianbro mounted its unit to
a skid. “Push-pull is a hazard in our book, and
we do all that we can to avoid it,” Mr. Chipman
says. “So, we mounted it to a skid and move it
with equipment. It is very portable for us because
we have fork trucks and loaders to move it around
our facility.” As a result, Vac-U-Max now offers
the model 1020 with an optional base designed
for forklifts.
“The great thing about this vacuum system is
that the hoses are long enough that we can leave
the collection drums where they can be mechan-
ically moved, instead moving drum dollies man-
ually,” Mr. Chipman says.
Since acquiring the vacuum, the facility has

The optimal tools for firearms manufacturers

The advanced materials and sophisticated designs of modern
firearms require tooling that delivers high precision, improved
finish, and extended tool life. Constructed of fine-grained
carbides and advanced coatings, Carmex tools are engineered
to deliver high performance, long life, and the precision
that enhances the reliability of your products.
Count on us for applications involving:
• Swiss-style machining Whatever your
• Thread milling requirements,
• Thread turning Carmex can provide
• Chamfering
the tooling to
• Groove milling
• I.D. and O.D. turning keep your
• Key slotting operation
• Special applications ON TARGET.

Contact your Carmex Representative

262-628-5030 or 888-628-5030
sales@carmexusa.com | www.carmexusa.com

The optimal tools for your industryTM

102 MMS January 2017 mmsonline.com

 WH EN Y O U R S UCCE S S

DE P EN D S ON TH E NU M B ER S

AF TER TH E DE CIM A L PO I NT

New!


MOBILE SURFACE
ROUGHNESS
MEASURING
INSTRUMENT –
MARSURF PS 10
WITH INTEGRATED
REMOVEABLE
DRIVE


mahrexactly.com/MarSurfPS10 WIRELESS
TECHNOLOGY

mahrexactly.com/WirelessGaging

Introducing MarSurf PS 10 - Mobile, Smart, Easy

The new generation MarSurf PS 10 portable roughness gage
Receive ‘Tips’ from
our Gaging Guru:
brings the capability of measuring 31 roughness parameters to
mahr.com/GagingTips
the point of manufacture. Using a smartphone-like 4.3” TFT
touch screen display, operation is fast, intuitive and user-friendly.
With its single button operation, convenient list of “favorite” M A H R F ED ER A L I NC .

1-800-343-2050
functions in the display and simple data storage/transfer, there is
mkt.nafta@mahr.com
no easier way to get laboratory-level performance on the www.mahr.com

shop floor.

SURFACE SHAFT HEIGHT CALIPERS & INDICATORS & AIR SNAP FORM PRECISION LENGTH
MEASUREMENT MEASUREMENT MEASUREMENT MICROMETERS COMPARATORS GAGING GAGES MEASUREMENT MEASUREMENT
BETTER PRODUCTION Shops Using Technology

cut the labor required to empty the blast machine
by more than 50 percent. The task of emptying
the pit, which used to take eight hours utilizing
two workers, now takes one worker three hours.
“Now, we can shut it down in the morning,
vacuum it out and have it repaired the same day
Vac-U-Max, call 800-822-8629
or visit vac-u-max.com.
using one person,” Mr. Chipman says. “The
reduced labor on maintenance, which is something
that cannot be billed, is now redistributed to
work hours on a project that is billable.”
Operations Manager Shawn Ramsay says
that, in addition to treducing the risk of injuries
and enabling quick and safe clearing of the
steel shot from the machine pit for maintenance,
the vacuum also has proved to be helpful in
the daily maintenance
and cleanliness of

Bye Bye, Burrs

the areas around the
machine.
In an environment
where the nature of a
blasting machine is to,
in effect, destroy itself
over time, reducing the
amount of wear and tear
can increase the longev-
ity of that equipment
and reduce the number
o f b r e a kd o w n s a n d
unscheduled downtime.
Because the vacuum
makes light work of the
heavy blast media, the
facility now cleans
around the blast cabinet
a n d a u g e r sy s te m a
couple times a week,
reducing abrasion to
machine parts.
Before getting the
vacuum, the machine
u se d to bre a k dow n
about once each month,
and all blast media
Front and Back hole deburring in a single pass! would need to be
removed for some type
E-Z Burr saves you time and money! Our long
lasting patented tools deburr holes in tough of unscheduled main-
materials in just seconds! Tools are available in all tenance or repair.
metric and fractional sizes from .040” through 2.0” After implementing
and custom deburring tools and be produced in 2 the vacuum, Mr. Chip-
to 3 weeks. View our complete list of products,
man says the company
sizes and capabilities at ezburr.com.
has only had to clean
www.ezburr.com 800.783.2877 Plymouth, MI Easy. Fast. Built to Last. the entire pit twice in
one year for unsched-
uled maintenance. This

104 MMS January 2017 mmsonline.com

 BETTER PRODUCTION
Shops Using Technology

Because the vacuum makes

light work of heavy blast media,
Cianbro now cleans around the
blast cabinet and auger system a
couple of times a week, reducing
abrasion to machine parts result-
ing in an 80 percent reduction in
unscheduled downtime.

is an 80 percent reduction in
unscheduled downtime,
w h i c h h a s l e d to i n c re a s e d
production time.
I n a d d i t i o n to u s i n g t h e
vacuum for its original task of
cleaning steel shot from the blast
machine and auger, Mr. Ramsay
says the facility has expanded
the use of the vacuum in other
applications, such as cleaning
garnet from the floor of another
blasting area, and also in the
paint bay. “It has allowed us
to clean the areas in a much
safer and expeditious manner,”
he says.
T he facilit y also use s the
vacuum to clean up overspray
in its coating operation as
well as for general housekeeping
on the shop floor. “When we
do a good clean up, we utilize
the vacuum. It is a lot faster
and more ef f icient than just
sweeping. And it gets it cleaner,”
Mr. Chipman says.

mmsonline.com January 2017 MMS 105

BETTER PRODUCTION Shops Using Technology
Toolholding for
Heavy-Duty Machining
M etal-removal rates during roughing and
heav y-dut y machining operations are
crucial for the productivity of the machining
HELLER MACHINE TOOLS
PROBLEM Needed to improve metal-
removal rates during roughing and
heavy-duty machining
SOLUTION Haimer Safe-Lock system with
drive pins and spiral grooves
RESULTS Performed high-feed slotting
of up to 2×D or more in difficult-to-
machine materials
106 MMS January 2017 mmsonline.com
operation. To improve these rates, German
machine tool builder Heller, whose U.S. head-
quarters are located in Troy, Michigan, focused
on the impor tance of the toolholder. Using
special shrink-fit chucks from Haimer USA (Villa
Park, Illinois) with drive pins and spiral grooves
in the tool shank to secure the cutter/holder
inter face, the company per forms high-feed
In a study, German machine tool builder Heller
performed a roughing operation in titanium without
the Safe-Lock. The tool pulled out of the standard
shrink-fit chuck and broke at 2×D. With Haimer’s
Safe-Lock holder, it was possible to reliably mill
full slots at 2×D.
 Rem Sales always proves
that my machine’s uptime
is important to them.
- Joel Montague, Plant Manager
Montague Manufacturing

PARTNER WITH THE WORLD LEADER

IN SMALL PART TURNING SOLUTIONS

Tsugami’s BW209Z 20 mm CNC Lathe offers simultaneous 3-Path Control on Dual Independent
Gang Slides, enabling diverse part processing, including pinch turning and pinch milling. Its standard
nine cutting axes and free, user-friendly Abile software will make easy work of your most complex
machining challenges.

866.224.8576 | www.remsales.com

SCAN THE CODE

FOR ADDITIONAL DETAILS
 BETTER PRODUCTION
Shops Using Technology
New
Coolant- slotting ranging to 2×D (50 mm) in difficult-to-
machine materials.

Thru! Especially within the aerospace, energy and

mechanical engineering sectors, production
managers must bridge the gap between economic
ef ficiency and high process reliability when
End Mill Holders working with materials that are difficult to machine.
He lle r, which produce s four- a nd f ive -a x is
CNC machining centers, CNC mill-turns, CNC
Deliver coolant where machines for crankshaf t and camshaf t
you need it! machining, and flexible manufacturing systems,
says it relies on close collaboration with its cus-
tomers, suppliers and research institutes to meet
ongoing demands in manufacturing. Often, the
aim is to increase productivity without compro-
mising process reliability.

• Flush Chips • Increase Tool Life

• CAT 40 and CAT 50
• Standard And Extended Length

Fitz-Rite Products, Inc. In order to equip toolholders with the Haimer

1122 Naughton, Troy, MI 48083
Phone: 800.835.2643
Safe-Lock system, spiral grooves are ground into
Fax: 248.528.1581 the tool shank. In combination with special drive
www keys within the chuck, the system prevents milling
cutters from getting pulled out of the chuck during
Made in U.S.A.
heavy-duty machining.

108 MMS January 2017 mmsonline.com

 Search When We Say
Machines “LIVE TOOLING”
Smarter. We Mean It!

Heimatec, a name you may not know…but you soon will.

Great reputations have a way of spreading.
A leading German supplier of live tooling, Heimatec
offers a wide assortment of tools for CNC lathes and
machining centers, plus the U-TEC® quick change system,
toolholders, multi-spindle drilling heads, specialty tools and
more. Application engineering, dealer and end user training
from our Chicago headquarters, plus a nationwide network
The Machine Tool Search Engine of quality machine tool reps and dealers to serve you.
NEW…LITERATURE DOWNLOADS ON LIVE TOOLING FOR
BRAND-SPECIFIC MACHINES…OKUMA, MAZAK, HAAS,
NAKAMURA AND MORE!
IN PARTNERSHIP WITH:

16 E. Piper Lane • Suite 129 • Prospect Heights, IL 60070

techspex.com 847-749-0633 • info@heimatecinc.com • www.heimatecinc.com
Preben Hansen, President

WITH
PRECISION
BOARD PLUS,
CREATIVITY
HAS NO LIMITS
Polyurethane Tooling Board
n Low-to-no dust machining n Non Toxic
n Large sheet sizes n No Outgassing
n Custom step tools n Non Abrasive

n Large blocks n Made in the USA

n 4 lb. to 75 lb. densities

(800) 845-0745 • www.precisionboard.com

New Material! Low-to-no dust! See the 22-second machining video on our website

mmsonline.com January 2017 MMS 109

BETTER PRODUCTION Shops Using Technology

the same technological values, but shortening

Werner Kirsten, technology developer at Heller,
presents his proof of concept findings.
“We often achieve this aim with an optimized
roughing operation that ultimately results in
a reduced finishing process. By maintaining
the finishing depth of cut by 50 percent, the
ove ra l l m ac h i n i n g ti m e i s re d u c e d to h a l f.
H owe ve r, t h i s r e q u i r e s p ro c e s s r e l i a b i l i t y
and controllable systems during roughing,”
says Werner Kirsten, who works in Heller’s
Technology Development Department on difficult-
to-machine materials.
All machining components in the process
chain must be considered to improve productiv-
ity, he says. The machine tool is the most evident
component of the machining process, however,
the tool, the toolholding system, the coolant
supply and other elements are also essential for
a successful operation. “In the end, the weakest
link of the process chain limits the success,”
Mr. Kirsten says.
For many shops, this weakest link is often
t h e to o l h o l d e r. I n t h e c a s e o f r e i n f o r c e d
shrink-fit chucks, however, the vibration node is
closer to the bearing point (due to the larger

MAKING
PRECISION TOOLS
IN THE USA FOR
SOLUTIONS
100 YEARS FOR A LARGE RANGE OF
1914 | 2014
DEBURRING
APPLICATIONS
THE SOURCE A WIDE ARRAY OF STANDARD SIZES
FOR DEBURRING CUSTOM TOOL DESIGNS AVAILABLE
1

ING
view more
DEBURRonline
cogsdill.com
1 Burraway and Burr-Off
mechanical hole-deburring
tools for removing burrs from
the front, back, or both sides
P 803.438.4000 of drilled holes in one pass.
F 803.438.5263 2 Flipcut – for back-
spotfacing and back- or front-
PO BOX 7007 chamfering operations; from
CAMDEN, SC one side, in one set-up.
29021-7007 3 SEDT – for deburring
holes in flat surfaces, angled
surfaces, and elliptical
surfaces.
2 3

COGSDILL TOOL PRODUCTS, INC.

©2017

110 MMS January 2017 mmsonline.com

 BETTER PRODUCTION
Shops Using Technology

Automation mass). T he re sult is a smoother machining

p r o c e s s w i t h l e s s v i b r a t i o n a n d a b e t te r
sur face f inish qualit y while using the same
Co
b o ts? -b tool, machine, proce ss parameters and
Ro ots fixturing technology.
IIoT? ? Heller conducted an ex tensive milling
application study in titanium Ti-6Al-4V for a
group of representatives from the aerospace
industry, the Technical University of Dortmund
and Technical University of Hamburg-Harburg.
T h e s tu d y u s e d a fo u r-a x i s H e l l e r H 5 0 0 0
with a gear unit and HSK-A100 spindle, which
y i e l d s to r q u e s r a n g i n g to 2. 2 9 0 N m, a n d
Inte
gra different 25-mm-diameter end mills to mill full
tion slots into a titanium plate. To simulate holder
? c o n d i ti o n s i n a e ro s p a c e a p p l i c ati o n s, th e
tools we re clamped into reinforced shrink-
fit chucks. At an axial cutting depth of 0.5 to

Questions? 1.0×D, the machining process was found to be

very reliable, Mr. Kirsten says. However, after
increasing to a full slotting depth of 2×D, the
tool pulled out of the shrink-fit chuck, creating
Pl
Safe
ty? De ant a slot closer to 2.5×D as it progressed through
sig the par t. Toward the end of the slot, the tool
n? finally broke due to increased cutting forces,
he says.
In this case, the clamping force of the chuck
was the limiting factor, he explains. As soon as
the axial pressure and process-related vibra-
tions we re to o high, the to ol move d ou t of
Perfo the chuck and further into the workpiece. At the
rm g?
Analy ance in same time, the cut ting pressure increased,
sis? Train the tool broke and the workpiece was damaged.
Mr. Kirsten says that the reason for this pullout
was that the tools we re forc e d to nav igate
With 25+ years experience in automation toward the spindle when the holding forces
were exceeded.
AMT is a one-stop solution for all your
That is where the Haimer Safe-Lock system
automation needs. Plan, Design, Test
comes into play. In addition to frictional clamping
& Integrate – It’s what we do. forces, the system has the same helix pattern as
the tool. Theoretically, even if the tool got loose
while using Safe-Lock, it would be pulled into
the holder through the helical drive keys and not
into the par t—a movement that could easily
preve nte d using le ngth pre set ting screws,
Mr. Kirsten says.
To test the Safe-Lock system, the Heller
technology developer repeated the trial, making
www.appliedmfg.com sales@appliedmfg.com
some major changes. Haimer Safe-Lock grooves

112 MMS January 2017 mmsonline.com

 INESS
CH INING BUS
R MA
YO U
RK ING
MA
N CH
BE

a ke s
hat M ?
W S ho p
aT op n s iv e benc
hmark in
a
g
t
p
a
r ogram
from su
for
rveys
e h e g d ps
s is a compr n d s iz es. Usin e s , T op Sho
op s
Top Sh types a ining b
usines
ational
and
s ho p s of all m a c h s o p e r
machin
e ber o f well a s in
t e d b y a num r p ra c tices as o m p e t itivenes
comple opfloo c la s s c ch
e s o p timal sh f in e w o r ld - le a d e rs of ea
identifi hat d e ar the
m e t r ic s t . E ach ye p.
b u s in e s s
a n u factu r in g
M a c h ine Sho
m odern
e parts
discret f e a t u red in M s
r y a re . shop
catego lea d ing U.S
pare to
rs com efforts
ce ind ic ato
p rovement
rforma
n uous im
u r key pe yo u r contin ctices
ow yo guid e ted pra
 See h a ta to ss -re la
rking d busine
benchma inin g- and hop
U se
o f top ma c h
rn M achine S ate
ode particip
t
abreas d in M o
 Stay r o file o w t
e to be
p out h ops
e chanc t an d find /topsh
 Ha v
6 rep o
lin
r e.com
k out the 201 m at mmson
Chec progra
nex t year’s
in

pS hops
e.co m/ To
onlin
mms
BETTER PRODUCTION Shops Using Technology
we re add e d on simila r solid c a r bid e to ols,
and the application was run again with a
reduced spindle taper interface (HSK 63 instead
o f H S K 10 0 ); a l e s s - r i g i d f i v e - a x i s , g e a r-
driven spindle; and a less-stable diagonally
fixtured workpiece.
Despite these additional limiting factors, the
tool could process a full slot of 2×D (50 mm)
with complete process reliability, Mr. Kirsten
says. “This way, we were able to indirectly prove
that Safe-Lock works and that the shrinking
technology has even more potential with HSK-
A100, especially on five-axis machining centers
with gear spindles.”
According to Mr. Kirsten, this is a reliable
process for roughing operations. He considers
th e H a i m e r S afe - Lo c k sy s te m a p r a c ti c a l,
easy-to-handle and process-reliable addition
Haimer USA, call 866-837-3265
or visit haimer-usa.com.
114 MMS January 2017 mmsonline.com
to th e s h r i n k i n g te c h n o l o g y, w h i c h H e l l e r
a lre ad y u tilize s w ith sta nda rdize d to ols of
other manufactures.
R e c o g n i z i n g t h e p ote n t i a l of t h e S a f e -
L o c k s y s te m, H a i m e r c r e a te d a l i c e n s i n g
program to give tool manufacturers the ability
to integrate the patented pullout protection
system into their tools. The company says
that, to date, 14 cutting tool manufacturers
have signed a licensing agreement, including
Walter, Widia, Sandvik Coromant, Seco Tools,
Sumitomo, Kennametal, Helical, Emuge Franken,
Data Flute, Niagara, OSG, Melin, SGS Tools
and Mapal.
According to Haimer, the Safe-Lock system
is moving toward becoming a standard for
h e av y m ac hining a nd rou g hing, a nd more
and more companies that make use of the
trochoidal (dynamic) milling strategy are also
making the switch to Safe-Lock holders to
prevent pullout.
 SAVE THE DATE
June 14-15, 2017
DONALD E. STEPHENS CONVENTION CENTER | ROSEMONT, IL, USA

A M E R I M O L D E X P O . C O M

Exhibit Hall Amerimold Tech Talks

featuring machine tools,
mold components, tooling,
materials, software, more
Business Development
Opportunities
for mold builders
and mold buyers
on designing, machining,
maintaining molds
BOOTH SALES ARE OPEN
Reserve Early and Save!
Sales@amerimold.com
CO-LOCATED WITH:

PRESENTED BY:
TOOLING AND WORKHOLDING
SHOULDER MILLING SYSTEM
PRODUCES 90-DEGREE PROFILES
Ceratizit says its MaxiMill 491 milling system
provides eight cutting edges per insert along with
easy handling. This shoulder-milling system
produces profiles of exactly 90 degrees, the
company says. Inser ts in the Blackstar and
Silverstar grades are said to make the tooling
system highly economical. Overall tool-change
times are reduced since the system is suitable for
both roughing and finishing, and the new insert
seat design simplifies quick insert changes. The
company says that the inserts achieve high axial
and radial runout, long tool life and high-quality
surface finishes. Their irregular pitch and optimally
adapted approach angles reduce vibration and
smooth the cut with low power consumption.
Ceratizit USA, call 800-783-2280
or visit ceratizit.com.
EXPANDED DRILL SERIES
EASES INSERT REPLACEMENT
Tungaloy has expanded its DrillMeister series of
changeable-head drills. The drill body lineup is
EDITOR JEDD COLE , jcole@mmsonline.com
116 MMS January 2017 mmsonline.com
now expanded to 12×D in
addition to the existing
8×D range. DrillMeister
has a self-clamping
system, designed to enable
fast and easy drill head
replacements. The insert
can be replaced without
removing the drill body
f rom the toolholde r or
machine spindle, signifi-
c a n t l y r e d u c i n g to o l -
change time and eliminat-
ing a need for readjustment
or resetting.
The new 12×D drill body covers drill diameters
from 12.0 to 22.9 mm, providing deep-hole drill-
ing performance with components such as drive
shafts and baffle plates for heat exchangers. The
optimized helical flutes on the drill body are sur-
face treated for smooth chip evacuation, making
DrillMeister capable of deep drilling where chip
evacuation is usually difficult.
Tungaloy America Inc., call 888-554-8394
or visit tungaloyamerica.com.
REAMING SYSTEM ADDS
FOUR CUTTING BLADES,
EXTENDS RECONDITIONING LIFE
Monaghan Tooling Group is now the exclusive
master distributor of Diatool’s Top Speed Ring
(TSR) modular reaming system featuring four
additional cutting blades. According to the sup-
plier, the reamers can be reconditioned as long
as the reamer body is in good condition, approx-
imately 10 times or more.
The reamer is designed for easy assembly and
Versatile grade for high-speed turning of cast iron
Al2O3 layer is 1.7 times thicker than the conventional coating
Strong adhesion between coating and substrate delivers remarkable toughness

Special surface technology www.tungaloyamerica.com

TOOLING AND WORKHOLDING

does not require a pilot steps. Short holders with cylindrical shanks
diameter setting. or module flange connections enable runout
Other features compensation.
include modula r Monaghan Tooling Group, call 800-732-4565
reaming rings or visit monaghantooling.com.
ra nging f rom 50
t o 15 0 m m i n HIGH-FEED MILLING CUTTER
d i a m e t e r, s t e e l PROVIDES HIGH STABILITY FOR
body construction IMPROVED FEED CAPACITY
with carbide or Sandvik Coromant’s CoroMill 415 high-feed
cermet blades milling cutter for diameters ranging from 13 to
and various 25 mm (0.5" to 1") provides enhanced security
coating options, with the iLock insert seat interface and high metal
and holders with internal coolant supply. removal rates thanks to high cutter density and
The TSR provides versatility by allowing for a feed capacity.
left-hand helix or straight-fluted standard options The iLock insert seat interface is designed to
as well as different geometries, face cutting and deliver high stability and reduce the potential for
scrapping the workpiece. The insert seat itself
For more cutting tool information, ensures that the small inserts are easier to handle,
visit mmsonline.com/cuttingtools. the company says. The cutter density and feed
For workholding information, capacity are supplemented by the cutter’s extra-
visit mmsonline.com/workholding. close H pitch, which can be deployed thanks to

QUICK•POINT®
zero-point
clamping system
• tremendous reduction
of set-up times
• Repeatability < .0002”,
Clamping force of 13227lbs
• suited for almost
any machining center

lang-technovation.com

118 MMS January 2017 mmsonline.com

Tiger·tec® Gold
Go for better,
go for Gold.

For those who won’t settle for anything but the best: Tiger·tec® Gold
If you had to make a choice right now – between maximum tool life, uncompromising process
reliability and optimum productivity – which one would you pick? Why not choose the freedom
to never have to choose again. Stay true to your own high standards in every way.
Choose Tiger·tec® Gold.

walter-tools.com/us
TOOLING AND WORKHOLDING

the tool’s inherently high stability, ensuring more mm (0.0001") at 2.5×D,

than one tooth is always engaged in the cut. Each the Tendo E Compact
of the inserts offer four cutting edges. protects the machine
The CoroMill 415 is also available with the spindle and the cutting
Coromant EH (Exchangeable Head) interface, tool from damage. The
which the company says enables shops to hyd rau li c ex pa ns i o n
reduce their tooling inventor y and minimize toolholder is suitable for
machine downtime. applications ranging
Sandvik Coromant Co., call 800-726-3845 from rough milling to
or visit sandvik.coromant.com/us. finish operations such
as reaming and fine mill-
HYDRAULIC EXPANSION ing, the company says.
TOOLHOLDER TRANSFERS Tools can be quickly
520 NM OF TORQUE changed with an allen
Schunk’s Tendo E Compact toolholder eliminates key, making this hydrau-
the need for different holder technologies for lic expansion toolholder an alternative for opera-
milling, drilling and reaming. This hydraulic expan- tions in which the toolholder quantities do not
sion toolholder is designed to safely transfer justify peripheral equipment purchases. Common
torques ranging to 520 Nm (384 foot-pounds) at spindle connections are available, including HSK-
a 20-mm clamping diameter and is well-suited A63, SK40, BT40, CAT40 and CAT50 interfaces.
for high-volume cutting. With good vibration Schunk, call 800-772-4865
damping and runout accuracy of less than 0.003 or visit us.schunk.com.

YMW TAPS USA

Z-PRO
Economical High Performance Taps
Quality.

Consistency.
YAMAWA

YAM WA

1507 E. McFadden Ave. Santa Ana, CA 92705

YA

YA
M
M

Customer Service 855-YMW-USA1 855-969-8721

AW

A
A

W
Ph:714-782-0960 Fx: 714-380-6324
Performance.
A

www.ymwtapsusa.com

120 MMS January 2017 mmsonline.com

 [ HANDLES HIGH PRESSURE MACHINING

KURT DOVELOCK™ ]

For aggressive dovetail holding

> DoveLock provides access to 5 sides of the part
> Pre-hardened 4140 steel design maintains part
rigidity, minimizes deflection or clamp creep
> Reversible jaw for wide range of Dovetail widths
> Embedded locating pin for accurate part locating
> Mounting base has pre-configured hole patterns to
fit most machines
> Multiple pallet options available – consult factory
> Two sizes available: 1” and 2” jaw widths

www.kurtworkholding.com
TOOLING AND WORKHOLDING

BORING HEAD SYSTEM digital readout (DRO) module. A single universal

FEATURES UNIVERSAL DRO module can be used to set any number of
DIGITAL READOUT MODULE tools that have docking ports. With an easy-to-
The Wohlhaupter VarioBore precision boring head read display, the module provides accuracy of
system, available from Allied Machine & Engineer- 0.0001" (0.002 mm) on the diameter with setting
ing, is said to improve productivity through ease accuracy of ±1 micron. The battery enables as
and accuracy of adjustment and to virtually elim- many as 5,000 settings and is switched off after
inate scrap because 30 sec. The detachable module remembers the
of its exact adjust- last setting, even when it is detached. The module
ments. With a range is coolant-sealed to IP 65. The system uses
of 0.016" to 5.985" selected Wohlhaupter 019, MiniDigi, PrimeBore
(0.4 to 152 mm), the and DigiBore tooling.
boring head provides Allied Machine & Engineering,
an accuracy of call 800-321-5537 or visit alliedmachine.com.
0.0001" (0.002 mm)
o n d i a m e te r, a n d PCD FACE MILLING SYSTEM’S
speeds ranging to DIAMETER CUTS LARGE PARTS IN
30,000 rpm. FEWER PASSES
The boring head The KBDM polycrystalline diamond (PCD) face
can be used alone milling system from Kennametal is designed for
or with a dock ing high-volume machining, with standard sizes rang-
por t and universal ing from 2.5" to 8.0" (63 to 200 mm) and cutter

Quick & Easy

CUSTOM MADE ENDMILLS 2 Week
Lead Time

Made To Order
Solid Carbide
High Performance
.2500’’ - 1.00” DIA.
Neck Lengths & Radius
PVD Coatings
Economical Pricing

636-498-0370
sales@jstoolinc.com www.jstoolinc.com

122 MMS January 2017 mmsonline.com

 TOOLING AND WORKHOLDING

full face wipers, standard cartridge inserts, and

0.5" (12.7-mm) axial cutters for heavy roughing
and shoulder cutting.
In the case of automotive manufacturing, the
company reports that this tool system can achieve
finishes of 2 to 3 microns Ra and long tool life.
Additionally, Kennametal has developed two PCD
grades to meet the needs of automakers using
their own proprietary aluminum alloys. The KD1400
uses small diamond grains and offers good chip-
ping resistance and wear attributes, while the
diameters ranging to 21.5" (550 mm). According KD1425 uses large diamond grains, improving
to the company, these wide diameters enable the abrasion resistance and thermal stability and only
machining of large components, such as automo- slightly lowering performance where chipping is
tive components, in a single pass. Options for a concern. Both are capable of very high cutting
parameters, the company says; depending on
integral shank bodies, HSK mounting and left-hand
the alloy and setup rigidity, Kennametal recom-
cutter rotation are available, as well as special
edge preparations and nose radii. mends an initial cutting speed of 3,280 fpm
This face milling platform uses a fine-pitch(1,000 m/min.) and feed rates of 0.004" per tooth
aluminum body with wedge-style clamps and (0.01 mm), although higher values are possible.
adjustable pockets. A variety of PCD inserts are Kennametal Inc., call 800-446-7738
available, from mini-tips for light finishing cuts to or visit kennametal.com.

mmsonline.com January 2017 MMS 123

TOOLING AND WORKHOLDING
DRILLING GRADE FOR CAST IRON
COUNTERACTS HIGH OPERATING
TEMPERATURES
Walter USA expands its insert range for cast
iron drilling with new diameters in the high-speed
Color Select P6005-WKK45C grade for Xtra-tec
B401x point drills. These new inserts are available
in diameters ranging
to 1.50" (37.99 mm).
With this expansion,
the Walter’s grade for
machining cast iron
can now be used to
drill all holes from
0.47" to 1.50" (12 to
37.99 mm) in diameter at depths ranging to
7×D and holes ranging from 0.71" to 1.02" (18 to
25.80 mm) in diameter at hole depths ranging
to 10×D.
Cast iron properties such as brittleness as
well as irregular structures and surfaces exert a
great deal of stress on cutting edges, which can
HOLD IT
with extreme accuracy, precision and flexibility
Make it te-CO
if you want to reduce
costs and set-up time, maximize
flexibility and productivity, and
consistently produce quality parts.
Also available in hydraulic configurations.
www.te-co.com 800-543-4071
124 MMS January 2017 mmsonline.com
result in high operating temperatures. The sub-
strate, coating and geometr y of the P6005-
WKK45C insert work to counteract these condi-
tions, the company says. The insert’s multilayer
PVD coating combines tough and wear-resistant
layers to optimize hardness and toughness.
According to the company, these characteristics
give the new inserts as much as 100 percent
more strength on the cutting edge and outstand-
ing resistance to wear and high temperatures.
They also are said to provide great process
reliability when drilling and withdrawing from
deep holes, even at very large diameters. The
red ISO K coating used on the Color Select
WKK45C range allows users to easily gage the
amount of wear on the insert.
Walter USA LLC, call 800-945-5554
or visit walter-tools.com/us.
END MILL GEOMETRY ENABLES
DOUBLED FEED RATES
Niagara Cutter, a subsidiary of Seco Tools, recently
RT I FI E
E
D
C
ISO
9001
 TOOLING AND WORKHOLDING

launched its Stabilizer 2.0 nex t-

generation family of end mills. The
cutters in this series incorporate
continuous, variable, asymmetrical
geometries and provide smooth
and chatter-free performance that
c a n e n a b l e d o u b l e d fe e d r ate s
compared with previous models, the
company says. Because they handle
twice the chip load, the new versions
are said to substantially shorten part
Front and back,

Chamfer & Deburr

machining cycle times and further
boost productivity.
The family includes the ST430.2 fast, precise, controlled,
series designed for steels, alloy steels all in one operation
and cast iron as well as the ST440.2 HT series for

COFA SNAP DEFA GH-S

ISO-M and ISO-S materials such as stainless steel,
titanium and high-temp alloys. In addition to the
performance boost provided by the new geom-
etry, an advanced AlTiN coating offers resistance
to heat and abrasion to optimize tool life.
The end mills are available in diameters rang-
ing from 0.125" to 1.0" and 3 to 25 mm, with square
corner and corner radii ranging from 0.010" to
0.120", depending on series and diameter. Lengths
are available in 1×D, 2×D and 3×D.
Niagara Cutter, call 248-528-5200
or visit niagaracutter.com.

MILLING TOOLS USE

SELF-ROTATING INSERTS FOR
UNIFORM CUTTING EDGE WEAR
Pokolm’s Spinworx milling system is designed to
reduce operating labor time with self-rotating
cutting inser ts. Among the cutting materials
ava il a b l e fo r th e S p inwo r x syste m a re th e
new P25, P40, K10 and M35 grades offered in
high-precision and ground variants. The M35,
the company notes, is ef fective for cut ting
temperature-resistant metals, titanium alloys and
stainless steels. In addition, the company has Starting at 2mm/.079”
developed an improved seat and broader race
for higher process safety.
The cutting edges of the circular, self-rotating
discs are worn down completely uniformly along
their circumference, eliminating the need for
manual insert readjustment. For Product Videos & Brochures Visit
Pokolm Frästechnik GmbH & Co. KG,
call 49 5247 9361 0 or visit pokolm.de.
www.HeuleTool.com
mmsonline.com January 2017 MMS 125
SYSTEMS AND SOFTWARE
CAM SOFTWARE’S ROUGHING
STRATEGY BOOSTS
LATHE PRODUCTIVITY
DP Technology’s Esprit CAM software features
ProfitTurning, a lathe roughing strategy designed
to significantly reduce machine cycle time, increase
precision and improve quality control. This high-
speed roughing strategy for OD, ID, face cutting
and other tasks is said to be fast, secure and
efficient while extending tool life through minimized
wear. The ProfitTurning tool path maintains con-
sistent cutting forces and chip loads, enabling
increased cutting speeds, the company says.
EDITOR JEDD COLE , jcole@mmsonline.com
126 MMS January 2017 mmsonline.com
By employing trochoidal turning and controlled
engagement techniques, the toolpath strategy
also reduces vibration and residual stresses, which
makes it well-suited to thin walls or hard materials,
especially super alloys, the company says.
Esprit 2016 uses a physics-based cutting
engine that formulates unique strategies for each
cutting challenge and provides the foundation for
technologies such as ProfitTurning. The software
inputs all relevant factors in the toolpath algorithm
such as tool material, tool shape, workpiece
material, tool speed, feed rate, chip deforming,
chip load, machine tool power, acceleration and
deceleration. This helps to establish complete
control of the cutting environment, allowing for
optimal cutting everywhere along the tool path,
the company says.
Esprit by DP Technology Corp.,
call 800-627-8479 or visit espritcam.com.
CAD/CAM SOFTWARE
RELEASE SAVES TIME
WITH OPTIMIZED FEATURES
Tebis America introduces Version 4.0, Release 3
of its Tebis CAD/CAM software. The highlights of
 SYSTEMS AND SOFTWARE

the new launch include toolbars and menu panels of 2.5D drilling and milling is also more efficient
that can be easily docked to the edge of the in this version, because the processing sequence
application window; a more intuitive software in feature-based NC programming now can be
interface for new users; and a new project dialog more easily influenced by feature groups. Tool
that displays after the program starts displaying optimization has also been extended in the Job
the most recently used files. In this version, Tebis Manager. Tools can be changed across machin-
has also improved the display of wireframe models ing operations in NCJobs.
and isolines to avoid the problem of too many According to the company, it is possible to
i s o l i n e s o n t h e s c r e e n t h a t c a n m a ke t h e shorten cycle times by roughly 30 percent in
components visually
unclear. This version is
a l s o d e s i g n e d to b e
more ef ficient with When the coolant becomes a Liquid Tool.
users’ time, automati-
cally breaking up
assemblies and com-
plex files into multiple
individual files. Another
time-saving benefit is
optimized reverse
engineering. Release 3
provides improved
algorithms that gener-
ate transitions for four-
edge surfaces. The user
can also quickly adjust
the approximation
tolerance, control-
generated radius run-
outs a nd the oretic al
edges more efficiently.
In surface modeling,
when generating sur-
f a c e s w i th c o n s t a n t
cur vature, Release 3
supports symmetrical Metalworking fluids to
areas and provides optimize productivity,
better management of economic efficiency
input parameters when and machining quality.
using optimization func-
tions. This version also
delivers improved reli-
ability in NC programs. Our specialists support you to get the best out of your machines and tools with
A n ex tended list of the Liquid Tool. Please contact us for your local distributor.
known machine con-
flicts is integrated into
the CAD/CAM software
for quick access. Blaser Swisslube Inc. Goshen, New York Phone 845-294-3200 mailboxusa@blaser.com www.blaser.com

The NC automation

mmsonline.com January 2017 MMS 127

 SYSTEMS AND SOFTWARE
AUTOMATION THAT PAYS FOR ITSELF
Affordable Lights-Out Solutions - Built to Suit
laser cutting and trimming because the improved
Small Conveyors NC point distribution results in more compact
Accumulators
Uni-Mateª programs. The user can set axial tolerances and
manually remove NC points. Head tilt directions
Ask for a quote. on the machines also can be handled more easily
800-586-4585 in stamping areas. This prevents rapid pivot
movements. Tool paths can be checked numer-
ically with the Collision Check Machine add-on
MINI-MOVER CONVEYORS
MADE IN THE USA www.mini-mover.com to avoid collisions and limit-switch conflicts.
Tebis America Inc., call 877-748-3247
or visit tebis.com.

HMI ACCOMMODATES MULTIPLE

ETHERNET PROTOCOLS
The Predator Touch human-machine interface
Machine Tool Components (HMI) from Shop Floor Automations (SFA) features
a large-button interface designed to make it easier
to send and receive machining programs. Other
features include data collection, various access
options, consolidation of automation platforms
Spring Plungers and button customization.
While Touch HMI is the front end for machinists,
multiple Ethernet protocols can be used on the
back end. FANUC Focas enables file transfers to
and from CNC memory without ever needing to
touch the CNC control, and can be leveraged for
Clamps machine monitoring in the future without the added
cost of hardware. It can also prove to be a safer
API than others, the company says. Predator
SecureDNC facilitates encrypted file transfers
directly into the CNC control’s memory, enabling
the user to add any Windows-based machine tool
to the network. Users can load Touch HMI directly
Workholding Grippers
onto select CNC controls. Common controls
include Mazak and Okuma, plus certain Haas and
DMG MORI controls. The HMI can also use FTP,

Fixturing Accessories
®

Rollers & Bumpers

www.fixtureworks.com
Fraser, Michigan
888.794.6887

128 MMS January 2017 mmsonline.com

 SYSTEMS AND SOFTWARE

a common protocol for file transfer. to shorten cycle times. SpeedPro is installed
Shop Floor Automations Inc., call 877-611-5825 directly on machine tool controllers and displayed
or visit shopfloorautomations.com. as an option on the machine tool interface.
According to ITRI, the software is the first such
MACHINE MONITORING, product incorporating theories of cutting force
SIMULATION SOFTWARE rather than only considering geometrical preci-
MODULATES FEED RATES sion. The product reduces the trial-and-error to
ALONG TOOL PATH find process parameters and increase overall
Industrial Technology Research Institute (ITRI) performance and productivity. The software not
offers SpeedPro, a software suite designed to only eases the process of finding feasible feed
improve the safety and productivity of machining rate values, but also enables cutting force calcu-
operations through machining process simulation lations and feed rate value modulations along the
and optimization of tool paths, particularly in thetool path. Users can optimize NC programs on-site
aerospace and automotive industries. The software and increase productivity without access to the
can process programs on machine tools prior to original CAM program.
actual machining. It geometrically simulates mate- Industrial Technology Research Institute,
rial removal and updates part geometry, evaluates call 886-3-582-0100 or visit itri.org.tw/eng.
machining performance, and displays cutter and
machine tool spindle loads. It also optimizes
For more information about systems and
process feed rates to take corrective actions and
software, go to mmsonline.com/erp and
eliminate machining failures, reduce scrap parts
mmsonline.com/cam.
and increase the speed of conservative programs

mmsonline.com January 2017 MMS 129

MODERN EQUIPMENT REVIEW Spotlight: Turning
AUTOMATIC LATHE AVAILABLE
“INDUSTRY 4.0-READY”
The new generation of Index’s ABC automatic
lathe is designed for turning simple to moderately
complex parts in cycle times as much as 15 per-
cent faster than the previous generation, with
rapid spindle acceleration (8 G), shorter spindle
ramp-up times, higher rapid traverse rates and
quick chip-to-chip times. Ideal for runs ranging
from 5,000 to 50,000 parts in the 42- to 60-mm
range, the machine’s combination of features
supports a very low production cost per piece,
even for complex parts, the company says.
The machine is available in two-, three- or
four-axis versions. As many as 19 tools are avail-
able for highly flexible machining with live tools
for both turrets. Simultaneous machining with as
many as three tools promotes shorter cycle times.
The ABC is equipped with as many as five driven
backworking tools and offers driven tools in all
turret positions.
130 MMS January 2017 mmsonline.com
The motorized 27-kW, 6,000-rpm spindle can
generate up to 95 Nm of torque. The upper turret,
mounted above the main spindle, is used typically
for ID work, while the lower turret is used mainly
for OD work. A synchronized spindle operates in
the upper turret. Both turrets provide a rapid
traverse of 36 m/min.
The lathe is equipped with an 18.5" touchscreen,
IndexC200-2D CNC and the company’s Xpanel
i4.0 operating system. Xpanel makes the machine
“Industr y 4.0-ready,” the company says. The
operating system focuses on the optimal control
of the machine for the effective machining of
workpieces with ma ximum productivity, and
provides a direct connection between the machine
control and the operations depar tment. The
operator receives exactly the information that best
supports the current work. Xpanel offers extensive
user assistance through complete integration into
existing network structures. Drawings, setup
sheets, user manuals, circuit and hydraulic dia-
grams, and more are available directly on the
machine without additional hardware.
The ABC can handle heav y-duty polygon
turning and thread milling with a counterspindle
or drive attachment. The machine also can be
supplied with a quiet-running Index bar loader,
which can save anywhere from 4 to 30 sec. per
cycle. It can also be equipped with automatic part
unloader automation.
Index Corp., call 317-770-6300
or visit indextraub.com.
TURNING CENTER HANDLES
4,500-MM SHAFTS REQUIRING
LONGITUDINAL BORES
WFL has redesigned its M40 Millturn for turning
parts ranging to 520 mm in diameter, featuring an
optional 4,500-mm center distance to enable
efficient machining of longer, thinner shaft-type
parts that require deep, longitudinal bores. Design
 Spotlight: Turning MODERN EQUIPMENT REVIEW

have been installed in the tool magazine for tool-

station monitoring.
WFL Millturn Technologies Inc. - USA,
call 248-347-9390 or visit wfl-usa.com.

VERTICAL LATHE PRECISELY

MACHINES LARGE, HEAV Y PARTS
improvements aim to increase reliability and user- Okuma’s V920EX single-saddle vertical lathe
friendly access of the tool magazine, along with features a powerful turning spindle and a larger
other ergonomic
c h a n g e s. T h e r e d e -
signed operator panel
now has improved ergo-
n o m i c s f o r s h i f t i n g,
Your Threading Specialist!
improved access to the
integrated printer, more
space for optional con-
trol elements, optimized CHASERS
API Threading chasers!
cabling and improved • Buttress, WW, NPT, Rounds...
Superior coatings! Combination Bar
serviceability. Turning ,Threading and Facing
A key a d va nt a g e, All-in-one!

according to the com-

pany, is the enlarged FLO-LOCK ON-EDGE
steady-rest space, the
result of an improvement
in the layout of the
energy chains. A positive
secondary effect of this
is a longer service life
and increased reliability
LAYDOWN
Thousands of new items added to our
new Threading Catalog!
of the energy chains.
State of the art coatings!
A separate pickup Pressed, ground and raised chip breakers!

magazine is available
fo r ve r y l o n g a n d /o r
heavy tools. The maxi-
mum tool length has THREADMILLINGIndexible and solid threadmills!
been increased from
1,500 to 1,700 mm. The
disc magazine can be
extended to as many as
20 0 s t ati o n s. D i re c t
access to all tool stations
is still possible even

Call us! We can make it!

when using this
e x te n d e d m a g a z i n e
option, avoiding cum- Many are available in inventory!
bersome loading and Over 1 million inserts in stock!
unloading. In addition, 800-345-2815 or sales@toolflo.com
reliable optical sensors

mmsonline.com January 2017 MMS 131


ELIMINATE OIL /
COOLANT MIST & SMOKE
PROVIDE A HEALTHIER WORKPLACE
REDUCE ABSENTEEISM
CUT HVAC COSTS
• Exceeds OSHA & NIOSH requirements
• Easily installs on any CNC machine
• Eliminates oil/coolant mist, smoke, other
fine aerosols and particulates
To learn more, contact us at 513-528-5674,
mistcollectors@LNSamerica.com
or visit www.LNS-america.com.
Full Grip Jaws
• Aluminum, Steel, or Cast Iron - diameter size range from
6-inch to 36-inch
• Jaw heights range: 2-inch, 4-inch, and 6-inch
• Close tolerances and concentricity easily maintained.
• Allows for complete gripping of the work piece
• Special oversized jaws available
• Excellent for gripping thin-walled parts without distortion
• Machine and tool life extended due to lighter weight
jaws, reducing mechanical stress.
• Made in the USA
ISO 9001:2008
DillonManufacturing, Inc.
2115 Progress Drive | Springfield, Ohio 45505 |
Phone: 1-800-428-1133 | Fax: 1-800-634-6480 |
Email: sales4@dillonmfg.com | www.dillonmfg.com
132 MMS January 2017 mmsonline.com
MODERN EQUIPMENT REVIEW
Spotlight: Turning
work envelope, making it ideal for cutting a vari-
ety of large, heavy parts. The machine’s work
envelope provides a maximum turning diameter
of 36.22" plus 33.86" of swing over the saddle,
enabling it to accommodate large, odd-shaped
workpieces. Highly rigid construction and power-
ful ballscrews generate slideway movement to
both axes for precise machining. The lathe has a
maximum swing of 39.37", and a range of 20 to
1,250 rpm.
The V12 turret is said to enable maximum
machining productivity when paired with effective
chip discharge. Optional side or rear chip con-
veyors can be placed to match discharge direction
based on shopfloor requirements. Maintenance
tasks are simplified with easy access to the air
filter, hydraulic unit and coolant tank on the back
of the machine.
Okuma’s Thermo-Friendly Concept is standard
and automatically compensates for ambient
temperature changes to maintain tight tolerances.
Cycle times, lead times and energy costs are
significantly improved with Okuma’s open archi-
tecture OSP-P300L control and Eco suite feature.
Okuma America Corp., call 704-588-7000
or visit okuma.com/americas.
MULTITASKING SWISS-TYPE
LATHE ENABLES SINGLE-SETUP
MACHINING
Ganesh Machiner y’s twin-spindle, eight-axis
SL-20Y2 Swiss-type lathe is designed for “done-
 Spotlight: Turning
in-one” machining to complete the work without
follow-up operations that require fixtures and tie
up multiple machines and operators. According
to the company, it is capable of performing mul-
tiple operations on barstock as large as 0.75" in
diameter with all axial and radial milling features
accurately timed and deburred.
The 20-mm multitasking lathe can be operated
with or without a guide bushing for job flexibility.
The 10,000-rpm main spindle is powered by
MODERN EQUIPMENT REVIEW
a 5-hp spindle motor; the subspindle turns at
8,000 rpm. A toolholder accommodates 30 tools,
of which eight are driven using ER-16 collet
spindles. The main spindle can bring 17 tools to
work the part, and the subspindle can use 13
tools in the basic machine configuration. Many
tooling options are available to address the spe-
cific requirements of each workpiece. A high-
performance C axis on both the main and sub-
spindle provides accurately timed axial and radial
milling feature placement.
A parts catcher and parts conveyor facilitate
the removal of valuable parts from the machine
without any damage. A cutoff confirmation sweep-
arm switch is provided to ensure that the part is
separated from the barstock successfully. Cutting
oil flow confirmation monitoring ensures that the
cutting oil is properly lubricating the cutting tools.
In addition to the SL-20Y2 20-mm lathe, Ganesh
offers 32- and 42-mm models.
Ganesh Machinery, call 888-542-6374
or visit ganeshmachinery.com.
mmsonline.com January 2017 MMS 133
 MODERN EQUIPMENT REVIEW
Workholding Products Spotlight: Turning

NEVER BUILD ANOTHER FIXTURE REDESIGNED GANG-TYPE LATHE

DELIVERS LONG-TERM PRECISION
Want more power from The Wasino G-07 high-precision lathe has been
redesigned to employ the unified DMG MORI
your workholding? design. The machine’s gantry-type toolpost is

Raptor has it! said to reduce cycle times by achieving “zero

indexing time.” Featuring a long, 490-mm X-axis
travel, the lathe is said to provide the high accuracy
of a gang-type lathe, enabling more accurate
finishing and hard turning.
The G-07 lathe has a symmetrical structure
with respect to the spindle center, and the mini-
mum distance between the axis travel reference
guide and the spindle helps minimize the effects
of heat. Induction-hardened, single-piece hori-
zontal slideways integrated on the bed provide
good vibration damping, high thermal stability
EC 2015 – Sept. 15-17, Booth 1747
and high rigidity. The slideways’ resistance to
Simplify your process. Complete 95% of chatter makes it possible to lower the position of
your workpiece in one holding.
the center of gravity between the floor and the
In Stock and Ready to Ship! feed system, promoting stable machining accuracy
1-800-824-8333 RaptorWorkholding.com over the long term. The flat-V slideways on the Z
axis and dovetail slideway on the X-axis dovetail
ensure high rigidity and straightness. The ballscrew
support bearing is placed as close to the spindle
BROACHING as possible to suppress thermal displacement; a
TOOLS reliable pre-tension structure is also employed to
boost precision. Such features combine to enable
the G-07 to achieve dimensional accuracy of
3 microns even from a cold start and circularity
of 0.5 micron, the company says.

Successfully broach square, hex and

special shapes like these...Call Us!

Exclusive bearing design gives longest life.

Somma broach blanks cut freer and reduce spiraling.
Produce internal or external shapes on screw machines,
CNC lathes and other machines.

PREMIER TOOLING FOR THE MANUFACTURING INDUSTRY

109 Scott Road, Waterbury, CT 06705

PHONE (203) 753-2114 FAX (203) 756-5489 www.sommatool.com
Call Today for Our Free Tooling Catalog sales@sommatool.com

134 MMS January 2017 mmsonline.com

 Spotlight: Turning
DMG MORI provides several loader and
workpiece stocking systems as well as other
peripherals for this machine. Automation solutions
include gantry loaders, conveyors for material
loading and finished part unloading, single- and
two-axis palletizers, and rotary stockers. Periph-
erals include a part catcher, external measuring
unit and tool set ter to facilitate setups and
other tasks; a semi-dry unit, coolant chiller and
MODERN EQUIPMENT REVIEW
high-pressure coolant unit to support machining
operation; and a chip conveyor and mist collector
to maintain a clean work environment.
DMG MORI USA Inc., call 855-364-6674
or visit dmgmori.com.
TURNING CENTER SERIES
FEATURES COLLET-READY SPINDLE
Hardinge’s Talent series of CNC turning centers,
PR0TECT PARTS
from scratches and corrosion
• Replace fluid soaked cardboard with
reusable plastic mesh.
• Breathable plastic sheets and sleeves
cut to your sizes in one business day!
See a demo at /IndustrialNetting
1-800-328-8456 www.industrialnetting.com
mmsonline.com January 2017 MMS 135

A M E R I M O L D E X P O.CO M
BALL GAGE
Ball Gage instead of a cylindrical plug gage.
Save time with the self centering
spherical surface of the ball gage. When
measuring a large number of holes it can be
100 times faster.
Put one or two flats on the ball and find
any out-of-round holes. Measure how parallel
the space is between two surfaces and or
the size. You can get into inside diameters or
inside spherical surfaces of rod end bearings.
Bend the stem to reach inaccessible
locations, in confined areas, down in a hole,
inside a cavity or in a buried feature which
cannot be seen.
Mount the ball on a wire for flexibility to
go around corners in pipe and tubing, for
example.
Easily measure the width of grooves or the
surfaces of spherical and toroidal features.
Accurately measure the pitch diameter of
bearing races, threaded surfaces and of gears
BAL-tEc Division
Micro Surface Engr., Inc.
1550 E. Slauson Ave.
Los Angeles, CA 90011
323-582-7348 • www.precisionballs.com
136 MMS January 2017 mmsonline.com
MODERN EQUIPMENT REVIEW
Spotlight: Turning
including the 42 and 51 models, is designed for
accuracy, flexibility and durability in a compact
machine. The series offers two separate base
structures providing short and standard bed
lengths. The machines feature robust one-piece
cast iron bases, heavy-duty roller linear guide-
ways and ballscrews. The collet-ready design of
the main spindle and subspindle increases part
accuracy and improves surface finish, the com-
pany says.
The turning centers are equipped with through-
tool and headwall air/coolant for both the main
spindle and subspindle, foot switches, chip con-
veyor interface, bar-feed interface, and an air hose
with an air gun. A FANUC OiTF CNC is provided
as the control. Options include live tooling, Y axis,
servo tailstock and more.
Hardinge Inc., call 800-843-8801
or visit hardinge.com.
TURNING CENTER FEATURES
DIRECT-DRIVE MILLING SPINDLE
Mazak’s Quick Turn-250MSY turning center offers
several productivity-enhancing features including
a direct-drive turret design; a higher-torque main
spindle; a faster, more powerful milling spindle;
and the Mazatrol SmoothG CNC. This multitask-
ing turning machine has two turning spindles, a
rotary-tool milling spindle and Y-axis capabilities
for single-setup part processing operations. The
new 12-position, direct-drive turret eliminates the
use of belts for improved part surface finishes
and reduced maintenance, the company says.
 Optimize Your High-Volume
Hole Deburring Applications
– Guaranteed.

Standard or custom, Michigan Deburring tools work

better, last longer and lower your cost per hole.
• High-volume customs at standard tool pricing
• Deburr holes ranging from 1.5 to 25.5 mm
• Inventory maintenance (JIT) for fast delivery
• Consistent results • User friendly • Made in USA



www.mideburring.com
 1,,  810 -227-1000
/"" Brighton, Michigan

mmsonline.com January 2017 MMS 137

MODERN EQUIPMENT REVIEW Spotlight: Turning
The turret accepts both VDI and bolt-on tooling.
The turret’s direct-drive rotary tool spindle runs
at 10 hp and 6,000 rpm, providing 52 foot-pounds
of torque. Speeds ranging to 10,000 rpm are
available with an optional tooling package. The
headstock features a 10" main chuck mounted
on a 35-hp, 4,000-rpm integrated spindle motor
for heav y metal removal. T he main turning
spindle also serves as a C axis programmable in
0.0001-degree increments to accurately position
Your Next Stop for the Latest
Abrasive Blasting Solutions
Integrated robotic technology
Programmable manipulation for multiple nozzles
Pick & place and vision system capability
Ideal for parts with complex geometries
With authorized distributors in place world-wide,
good advice, technical information, and personal
service are just a click away. Visit our website to
request the name of a distributor near you.
ISO 9001:2008 certified
www.clemcoindustries.com
138 MMS January 2017 mmsonline.com
parts for square facing and slotting cuts as well
as precisely drilled holes. The C-axis spindle is a
full-function CNC-controlled axis for milling. A
second 15-hp, 6,000-rpm turning spindle with a
6" chuck enables the machine to turn small-
diameter workpieces with speed and accuracy.
The Mazatrol SmoothC and SmoothG CNCs
offer EIA/ISO programming as well as conversa-
tional programming for generating complex drill-
ing, milling or tapping programs. The controls
also feature advanced hardware and software
functions that promote productivity and perfor-
mance accuracy in challenging part production
operations. The SmoothG incorporates a variety
of advanced programming functions for ease of
use and high-speed, high-accuracy machining
performance, such as High Gain Feed Forward
Control, Fast Rotary Axis Speeds, Variable Accel-
eration Control and Intelligent Pocket Milling.
A v a r i e t y of a u to m a t i o n s t r a te g i e s c a n
be integrated with the turning center, ranging
from an automatic bar feeder to gantry robots
Innovative
Workholding
Solutions
Vises Fixtures Cutters
5THAXIS.com
 MODERN EQUIPMENT REVIEW
Spotlight: Turning

for improved spindle utilization and a boost

in productivity.
Mazak Corp., call 859-342-1700
or visit mazakusa.com.

RIGID TURNING CENTER’S Y A XIS

TRAVEL EXTENDS TO 150 MM
Methods Machine Tools has expanded its Feeler
FT-series high performance CNC turning centers
with the FT-250SY. The machine features a true
Y axis with 100 mm (±50 mm) of travel, which
provides increased rigidity for more robust machin-
ing. Also, by offering an 8" subspindle in addition
to the primary 10" spindle, the machine provides
more capacity than comparable turning centers,
the company says.
The machine’s single-piece structure with box
ways, a 45-degree slant bed and robust base
contribute to high vibration damping. Extra rigid-
ity from a heavy-duty, 12-station turret results in
high metal removal rates, good finishes and long-
term accuracy. For ma ximum integrit y, FE A
analysis is used to ensure a solid machine base
with structural rigidity and stability. The machine
also offers high capacity with a 30-hp, 3,500-rpm,
10" chuck diameter primary spindle in addition
to a 20-hp, 4,500-rpm, 8" chuck diameter sub-
spindle.
X-, Y- and Z-axis travels measure 8.2" ±0.3" ×
3.9" ±2" × 41.3" (210 ±10 × 100 ±50 × 1,050 mm).
The machine is equipped with a FANUC 31i-TB
CNC, and a BMT-65 tool system provides a solid
interface for toolholding. For machine component
longevity, a fully enclosed CE cabinet prevents
dust and fumes from entering.
Methods Machine Tools Inc., call 877-668-4262
or visit methodsmachine.com.

mmsonline.com January 2017 MMS 139

BUSINESS OPPORTUNITIES

To place your ad in this section,

contact Bill Caldwell at:
email billc@gardnerweb.com
phone 888-527-8826
fax 513-527-8801

CUSTOMIZED MARKING TOOLS

OUTSTANDING CUSTOMER SERVICE
OIL MIST & SMOKE STANDARD MARKING TOOLS FROM STOCK
IN YOUR SHOP? MADE FOR FASTER OPERATION
Quick Delivery
www.mistcollectors.com
Tel: 1-800-645-4174

PIPE NOTCHER
Make quick saddle notches in
pipe/tube up to 2" diameter.
Several Models Available
Phone 800-886-5418
Fax 810-632-6640
www.heckind.net

BENCHMARKING
YOUR MACHINING
BUSINESS
mmsonline.com/topshops

140 MMS January 2017 mmsonline.com


2L inc........................................................... 140
5th Axis Workholding.................................... 138
A
Absolute Machine Tools, Inc. ............................3
Accudyne Products LLC ............................... 125
Allied Machine & Engineering Corp..................58
amerimold.................................................... 115
ANCA ............................................................59
Applied Manufacturing Technologies............. 112
ARCH Global Precision ................................. 105
ARCH Specials............................................. 105
Atlas Bronze................................................. 140
Autodesk Ltd.................................................. 19
Aven Inc. ........................................................56
B G
Bal-tec......................................................... 136
Birchwood Technologies.................................94
Blaser Swisslube Inc..................................... 127
Bucci Industries USA, Inc. ............................ 114
C H
C.R. Onsrud Inc..............................................99
Camfil APC ....................................................96
Carmex Precision Tools, LLC ........................ 102
Ceratizit USA..................................................57
CGTech ....................................................... 100
Clausing Industrial Inc. ...................................35
Clemco Industries Corp. ............................... 138
Coastal Enterprises Co. ................................ 109
Cogsdill Tool Products Inc. ........................... 110
Cole Carbide Industries, Inc. ...........................54
D Iscar Metals, Inc. .................Inside Front Cover, 1
Digi-Pas USA, LLC ....................................... 133
*Regional insert/ad included in select copies only.
ADVERTISERS
Dillon Manufacturing, Inc. ............................. 132
Doosan Machine Tools America Corp. ............. 11
Duplomatic Automation USA......................... 135
E
Edge Factor ................................................. 6, 7
ELTOOL Corporation .................................... 135
Emuge Corp...................................................95
Expo Manufactura 2017 ..................................69
E-Z Burr Tool Company, Inc. ......................... 104
F
FANUC America Corporation ..........................29
FITZ-RITE Products Inc. ................................ 108
Fixtureworks ................................................ 128
Fryer Machine Systems................................... 17
GenSwiss .................................................... 133
GibbsCAM .......................................................9
GMN USA ......................................................64
Greenleaf Corp......................................... 60, 61
Haimer USA ...................................................46
Heck Industries ............................................ 140
Heimatec .................................................... 109
Heule Tool Corporation ................................. 125
HORN USA .................................................... 13
Hurco North America.................................... 4, 5
Hyundai WIA ..................................................27
I
Industrial Netting .......................................... 135
Ingersoll Cutting Tools ............ Inside Back Cover
mmsonline.com Janaury 2017 MMS 141
ADVERTISERS

J Milltronics USA, Inc. ....................................... 15

J&S Tool, Inc. ............................................... 122
Mini-Mover Conveyors .................................. 128
J.F. Berns Co., Inc. ....................................... 137
Mitsubishi Materials U.S.A. Corp. ....................49
J.W. Done Corp. .............................................68
Mitutoyo America Corporation ........................42
Johnford ..........................................................3
Modern Machine Shop ................................. 113

K
N
Kuka Robotics Corp. ......................................77
Niagara Cutter.................................. Back Cover
Kurt Manufacturing....................................... 121
Numberall Stamp & Tool Co., Inc. .................. 140

L
O
Lagun Engineering Solutions ..........................31
Okuma America Corporation ..........................43
LANG Technovation ..................................... 118
OSG USA, Inc. ...............................................45
LightShapes Canada ......................................37

LNS America Inc. ......................................... 132

P
PMTS 2017 ....................................................67

M PRAB, Inc. .....................................................53

Machinemonster.com ............................ 137, 139

Macoser, Inc. ............................................... 135

R
Raptor Workholding Products ....................... 134
Mahr Federal Inc. ......................................... 103
Rosler Metal Finishing USA, LLC .....................52
Mastercam/CNC Software, Inc........................21
Royal Products.............................. 97a, 97b, 140
Memex, Inc. ...................................................38

Methods Machine Tools, Inc............................23 S

Sandvik Coromant.......................................... 41
Michigan Deburring Tool ............................... 137
SCHUNK Inc. .................................................91
MicroCentric Corp. ................................... 92, 93
Schwanog LLC............................................. 101
Midaco Corporation ..................................... 123

Modern Machine Shop (ISSN 0026-8003) is published monthly and copyright © 2017 by Gardner Business Media Inc. 6915 Valley Ave.,
Cincinnati, OH 45244-3029. Telephone: (513) 527-8800. Printed in U.S.A. Periodicals postage paid at Cincinnati, OH and additional
mailing offices. All rights reserved.
POSTMASTER: Send address changes to Modern Machine Shop Magazine, 6915 Valley Ave., Cincinnati, OH 45244-3029. If
undeliverable, send Form 3579.
CANADA POST: Canada Returns to be sent to IMEX Global Solutions, P.O. Box 25542, London, ON N6C 6B2. Publications Mail
Agreement #40612608.

The information presented in this edition of Modern Machine Shop is believed to be accurate. In applying recommendations, how-
ever, you should exercise care and normal precautions to prevent personal injury and damage to facilities or products. In no case can
the authors or the publisher accept responsibility for personal injury or damages which may occur in working with methods and/or
materials presented herein, nor can the publisher assume responsibility for the validity of claims or performance of items appearing in
editorial presentations or advertisements in this publication. Contact information is provided to enable interested parties to conduct
further inquiry into specific products or services.

142 MMS January 2017 mmsonline.com *Regional insert/ad included in select copies only.
 ADVERTISERS

Seco Tools Inc.................................. Back Cover

Shear-Loc .................................................... 140 NATIONAL SALES OFFICES

CINCINNATI HQ
Smart Attend..................................................37
800-950-8020
SmartCAMcnc ........................................24, 129 Travis Egan Publisher
tegan@gardnerweb.com
SMTCL Americas ........................................... 51 Kent S. Luciano Associate Publisher
kluciano@gardnerweb.com
Somma Tool Co. Inc. .................................... 134
Brian E. Wertheimer District Manager
South Bend Lathe Company ...........................55 brianw@gardnerweb.com
phone 513-527-8800 fa x 513-527-8801
Southwestern Industries, Inc. .........................25
OHIO/EAST COAST
Sumitomo Electric Carbide Inc. .........................2 Bryce Ellis District Manager
bellis@gardnerweb.com
SwiftCarb ......................................................50 phone 513-527-8970 fa x 513-527-8801

CHICAGO/MIDWEST
T Joseph Campise District Manager
Taiwan External Trade jcampise@gardnerweb.com
phone 513-766-5862 fa x 513-766-5892
Development Council (TAITRA) .................. 111
John Campos District Manager
Techspex, Inc. ................................................97 jcampos@gardnerweb.com
phone 513-766-5861 fa x 513-766-5893
TECMA 2017 ..................................................65
DETROIT/MIDWEST/NEW ENGLAND
TE-CO ......................................................... 124 Mike Vohland District Manager
mvohland@gardnerweb.com
The MFG Meeting ...........................................63 phone 513-338-2183 fa x 513-766-5855

THINBIT .........................................................33 LOS ANGELES/WEST COAST

Stephen M. Kosloff Regional Vice President
TIMTOS 2017 ............................................... 111 skosloff@gardnerweb.com
phone 513-766-5857 fa x 513-766-5851
Tool-Flo Mfg., Inc.......................................... 131
Rick Brandt District Manager
TRAK Machine Tools ......................................25 rbrandt@gardnerweb.com
phone 513-766-5864 fa x 800-527-8801
Tsugami - Rem Sales .................................... 107
PITTSBURGH/EAST COAST
Tungaloy America ......................................... 117 Anthony Pavlik District Manager
apavlik@gardnerweb.com
phone 917-838-8734 fa x 800-527-8801
W
WALTER USA, Inc......................................... 119

Y
YCM .............................................................. 47

YG-1 Tool Company........................................39

YMW Taps U.S.A. ......................................... 120

*Regional insert/ad included in select copies only. mmsonline.com Janaury 2017 MMS 143
GARDNER BUSINESS INDEX Metalworking

November 2016 – 49.7

Industry shows clear improvment from where it was a year earlier.
of minimal growth. Exports continued their long
W ith a reading of 49.7, the Gardner Business
Index showed that the metalworking indus-
try in November was virtually unchanged from the
run of contraction; however, their subindex reached
its highest level since May 2015 and clearly has
previous month but reached its highest level since trended up since August 2015. Supplier deliveries
June 2015 (discounting a spike last March). The have lengthened since last March.
industry has clearly improved from the 43.2 read- While material prices continued to increase at
ing it posted one year earlier, in November 2015. a significant rate in the month, the rate of increase
New orders grew for just the third time since has decelerated since last June. Prices received
July 2015, while production increased for the third continued to decrease, and while they trended up
time in four months. Backlogs continued to contract, from November 2015 to August 2016, they have
Metalworking Business Index decreased at an accel-
100 erating rate the three
90 months since then.
Future business expec-
80
tations skyrocketed in
70 November, jumping more
than 12 points to 77.4,
60
the highest level for this
50 subindex since January
2012. Given the proxim-
40
ity of the surveying to the
30 presidential election, it
would seem reasonable
20
to conclude that the met-
10 alworking industr y is
bullish on President-elect
0
Donald Trump.
Jan-07
Jul-07
Jan-08

Jul-08
Jan-09
Jul-09

Jan-10

Jul-10

Jan-11

Jul-11

Jan-12
Jul-12

Jan-13

Jul-13

Jan-14
Jul-14

Jan-15

Jul-15

Jan-16

Jul-16

The aerospace indus-

try grew in November
but reached their highest level since last March after two months of contraction, jumping to its
and second highest level since June 2015. The second highest level since the survey began in
trend in backlogs shows that capacity utilization December 2011. Machinery/equipment also grew
should begin improving very soon. Employment for the fourth time in five months, and the primary
was essentially flat in November after one month metals industry grew at an accelerating rate for
the third month in a row. In fact, the primary metal
STEVEN R. KLINE, JR. subindex has improved dramatically from its levels
DIRECTOR OF MARKET INTELLIGENCE
in February through July. This is a positive sign for
GARDNER BUSINESS MEDIA INC.
the metalworking industry overall, since primary
Visit Steven’s blog at gardnerweb.com/ metals companies create the stock that eventually
economics/blog or email him at gets machined. Also, the job shops segment
skline2@gardnerweb.com. increased for the second time in three months,
reaching its highest level since February 2015.

144 MMS January 2017 mmsonline.com

THE ALL-NEW
STABILIZER 2.0
FROM NIAGARA
CUTTER CAN DOUBLE
YOUR FEED RATES.
IT’S JUST THAT GOOD.

GO TWICE AS FAST.

FOR MORE INFORMATION ON HOW STABILIZER 2.0

CAN BOOST YOUR PRODUCTIVITY, CONTACT US
AT 800-TEC-TEAM (800-832-8326).